My Quality Journey: Lessons Learned and Stories Told

Stepping into the realm of quality in the aerospace industry has been one of the most challenging and rewarding experiences of my career. The journey is strewn with lessons, some learned the hard way, and others through meticulous planning and execution. Here, I want to share some of these valuable insights, hoping they resonate with those passionate about quality and excellence.

Product Design and Development

1. Perfect Product Comes First

In aerospace, a perfect product is not just a goal; it's a necessity. I remember a project where a minor oversight in the design phase led to a critical failure during testing. That incident underscored the importance of precision. There's no room for adjustments once the product is deployed. Every component, every process must be meticulously planned and executed with precision.

2. Material Selection and Testing

Material selection, testing, and special processes play a crucial role in the success of your product. A rigorous screening and testing qualification process for all components and welds is imperative.

3. Consider Assembly and Integration Early

Think about assembly, integration, testing, and launch operations during the design phase, not afterward. All components must come together seamlessly for the system to function successfully. Creating interface control documents for all potential integrations is essential.

4. Mass Management

Mass is a critical parameter in aerospace. I learned this when an additional layer of paint can lead to increase in overall mass of the product. Measure everything possible; even the smallest addition can make a big difference.

5. Environmental Considerations

Thoroughly understanding the environment and duration in which your product will operate is crucial. Consider all possible load cases and failure modes during the product life cycle. This foresight can prevent unforeseen failures down the line.

Processes and Systems

6. Systems and Checklists: The Lifeline

The smallest misses can prove costly. Robust systems and checklists are crucial. These are not mere tick boxes but lifelines ensuring every aspect of the product and operation is flawless.

7. Strong Process Plans

Having a strong process plan, stringent stage-wise clearances, and a RACI matrix is essential for maintaining manufacturing quality. Don’t miss a step or deviate unless it is discussed and agreed upon without compromising the mission.

8. Clear Acceptance Criteria

Be clear with your acceptance criteria. Ranges, bounds, and tolerances must be well-defined to increase the chances of success.

9. Avoiding Reworks

Rework is painful and time-consuming. They minimise your chances of success. Avoid them to the maximum extent possible.

10. Functional Testing

Functional testing and extensive trials are necessary to iron out flaws in software and automatic sequences. There is no other way to achieve robustness.

Tools and Technology

11. Instruments and Sensors: The Brain

A perfectly chosen, calibrated machine is critical to success. Instruments and sensors act as the brain of your operation, providing the precision and reliability needed.

12. Experiment and Learn

Before attempting any process on the actual product, be it milling, drilling, or otherwise, experiment on samples. This practice saves time, money, and effort, preserving the integrity of the valuable product you've built.

Testing and Validation

13. Testing Beyond Limits

Every product needs to be tested beyond its maximum limit if the mission demands it. Understanding limits and factors of safety is essential to gain confidence in your system and product. Build fault tolerances into the systems.?

14. Data and Problem Solving

Data is everything. Implement a strong RCA (Root Cause Analysis) to identify defects and correct them. Be a problem solver and leverage information to enhance your chances of success.

Team and Culture

15. People Matter

Don't forget your people. Keep them well-rested, healthy, and hydrated. A motivated and well-cared-for team is essential for maintaining high-quality standards.

16. Quality Mindset

Mindset matters. Hire people who believe in product quality and understand that quality is the cornerstone of success.

17. Invest in Skills

Investing in skills and strong workmanship ethics is crucial. A skilled workforce ensures high-quality output.

18. Embracing Failures

Failures are inevitable. Embrace them, report them, and learn from them. Building better products requires patience and resilience.

Vendor and Stakeholder Management

19. Vendor Qualification

Stringent vendor qualification and inward inspection for components are crucial. Creating a win-win situation for all stakeholders ensures a successful quality program.

Logistics and Handling

20. Transportation, Handling and Storage

Define the scope for equipment transportation, handling, storage in consultation with the design and operations teams, create and follow procedures and ensure regular monitoring of storage condition of the equipment.?

The journey in aerospace quality is not easy yet immensely fulfilling. Each lesson learned is a step towards perfection, ensuring that we build not just products but legacies that go beyond the skies into orbit.