Aerostructures November 12, 2014 Vol. 24, No. 37 Saluting Aerostructures’ veterans “I attribute a lot of my success to the military as I learned many life lessons” n Jeff Richardso s Engineer em st Quality Sy Jacksonville vice: Navy Branch of Ser t for LLY stands ou A E R at h w to back e warmth “When I think tive duty, it’s th ort after ac of rs ea y 12 to p me about my pulling back in ip sh e th of t om the and excitemen oking down fr lo t, en m y lo dep members and a demanding all the family at g and in w e g d come us back, el ship’s bri w to r ie p e ed on th to greet me friends gather all dressed up e d ri b l fu ti u iss.” seeing my bea d a very nice k an g u h m ar w with a More than 500 current members of Aerostructures’ domestic workforce have served in the U.S. armed forces. In conjunction with this week’s observance of Veterans Day, Skylines asked several of these veterans to comment on what significance the annual holiday holds for them, what benefits they derived from serving in the military, and what memorable moments stick with them from their active duty days. (Continued) Tyson Just A350 Produ ction Superv isor San Marcos Branch of S ervice: Arm y “The signifi cance of Vete ran on this one day, we all ce s Day to me is knowin g that lebrate, as a who have g country, vete iven up so m rans uch for the livelihoods freedoms an that each of d us have. I h close brothe ave lost man rs in arms, p y very e ople I have But there is thoughts of some comfo d aily. rt, on Vetera that they are ns Day, kno not – and w wing ill never – b sacrifices.” e forgotten for their Editor: ext. 3635 / [email protected] Mail Zone 99B Craig Miller m Leader Production Tea Foley OE vice: Air Force Branch of Ser the 9/11 training while ic as b of t ou g in g been cut off “I was process g. After havin in en p ap h as r and see w x weeks, to hea terrorist attack si r fo s n ia il v defend ith ci st signed up to ju from contact w ou y at th y e countr gned up was an attack on th eling when I si fe e h T l. ea rr to war. My was kind of su we were going ow n t u b e, m ti ble for my ce to be responsi that it was pea g in av h , ed st joined at atly te a young age. (I skills were gre at s er h ot of perie lives 19.) But the ex at n g own life and th ai p m ca t in my firs ng a leader.” 17 and served a natural at bei as w I e iz al re e ence helped m Thomas Timm Non-Destruct ive Testing Tec hnician San Marcos Branch of Ser vice: Marine C orps “I feel honored to have a day set aside to giv those who serv e thanks for ed in the milit ar y armed forces humbled at th . I’m also e same time b ecause I do not done anything fe el extr I have gives in their ow aordinary to deserve this. E veryone n way – some serve in the m have given by ilitary, others serving the pu b lic, and some efforts of other support the s by being pro ductive memb We all do our ers of society. part… and we should all show ciation for oth our appreers every day.” Larry Crano ecialist d Automation Sp an g in m m ra og NC Pr Chula Vista Navy Branch of Service: it did e to me now than or m ns ea m ay D rvice was “I think Veterans My time in the se e. ic rv se e th in as e did a lot when I w r the most part, w fo d, an ar W d ol C icemen during the hting. Today’s serv fig al re no t bu g, many of sabre rattlin to harm’s way and in nt se ly nt ue eq ly or mentally and women are fr d – either physical re ar sc e m ho g in general are com is ignored by the at th , rt pa t os m e folks’ and, for th eciation for these pr ap e or m t lo a served public. I have of our elders who e ic rv se e th r fo served in service, as well as pecially those who es d an – s ar w us were treated in previo war horrific, they e th as w ly on ot all those Vietnam. N me. My thanks to ho e m ca ey th n he them.” like pariah w ilies who support m fa e th d an … who have served 2 David Rohm r Staff Enginee San Marcos orps vice: Marine C Branch of Ser me. As significance to l ia ec sp y er v holds Day is the “Veterans Day efore Veterans b ay d eme th , ow two-day comm e h T ). all Marines kn 10 . ov and early birthday (N Marine Corps’ ng the late 60’s ri u D l. ia ec sp and uely itary personnel il oration is uniq m s it on d re nable try sou became fashio it , 70’s, our coun ar W am tn to the Vie isrespect its veterans. Due military and d e th st n ai ag ived more to demonstrate personally rece I , ct fa of r te mat Marine in r being a U.S. veterans. As a fo n io at ir m es. tual ad did in the Stat er ev respect and ac I an th ed ts I visit eran. I am the foreign por ever to be a vet an th d u ro p e ce and now Today I’m mor one an about fa d as h y tr n u r co veterans, not pleased that ou ciation for its re p ans.” ap s ow sh for WWII veter d outwardly te ra st on em hat it d dissimilar to w Shawn I vey EH&S M an Chula Vis ager ta Branch o f Service : Army “I attribu te many life a lot of my succes s to the m le ilitary as second d ssons, grew as lea I learned ecis de safety into ion points and le r, was faced with arned ho s e w to inco plitskills. Bu veryday life. Yes, rporate t it also ta the milita ught sold ry taught efficientl ie y. I credit s my early rs how to act safe urvival military ly and start in th experien ce. I take e EH&S w fellow ve this day orld to m ter to thank y friends w ans and pay a sp a ll of my ecial trib ho never u te m have serv ade it ho to my clo m ed se his countr alongside Pat Til e. I still feel privil eged to lman, wh y.” o gave his all for Johnny Kelley hnician Calibration Tec San Marcos vice: Navy Branch of Ser rvice? my military se om fr e iv er d s did I world, from “What reward y places in the an m ain so to el lowed me to g al s, n io Getting to trav at n ld to third-wor fe. I have world powers r our way of li fo t ec sp re d an that, in dinary things understanding or r fo n io at ci appre inable.” developed an ould be unobta w , ld or w e th some parts of 3 China facility experiences two firsts in October Customer visit confirms Tianjin facility’s readiness to meet steep rise in Airbus A320neo production rates Aerostructures’ Tianjin original equipment facility in China is located a mere 200 yards away from the Airbus A320 Final Assembly Line (FAL) in the city. But the two operations got a lot closer as the result of two late October events. On Oct. 21, two Airbus executives paid a visit to the Tianjin OE site as part of an A320neo industrialization review. The next day, several Tianjin OE employees stopped by the Airbus FAL to benchmark Airbus’ one-piece manufacturing flow in action. “Not only was this the first time the Tianjin OE facility has received a visit from an end customer, it was also the first time Airbus has ever conducted an industrialization review at our site,” said Tianjin OE Industrial Transition & Operations Lead Paco Cossio. “These reviews normally take place in Chula Vista.” During an industrialization review (IQR), also known as a “rate readiness review,” suppliers present evidence to Airbus that they are prepared and ready to support planned production rate increases for specific programs. In this case, it was the A320neo program, for which the Tianjin OE facility provides composite fan cowl bond panels and longerons. On Oct. 21, Aerostructures’ Tianjin original equipment facility experienced two firsts – its initial visit by an end customer and the inaugural Airbus industrialization review at the site. During an industrialization review, also known as a “rate readiness review,” suppliers present evidence to Airbus that they are prepared and ready to support planned production rate increases for specific programs. In this case, it was the A320neo program, for which the Tianjin OE facility provides composite fan cowl bond panels and longerons. Pictured above (from left to right) are: Karen Shan; Ethan Xu; Paco Cossio; Wenzhou Wang; Joe Ramirez; Louis Jutras; Tianjin OE General Manager SengLiang Goh; Airbus Supply Chain Quality Manager Lilian Tardieux; Airbus Program Manager Benoit Letay; Michael Winer; Craig Bridges; Yuepeng Chen; and Mary Qiao. 4 From 91 nacelle sets next year to 680 in 2018 “Our team was so proud to show our customer what we have accomplished within the last 18 months since initiating operations at this site,” said Cossio. “This was a great opportunity for the Tianjin OE facility to demonstrate to our customer our commitment and preparation for the A320neo ramp up.” What does that ramp up entail? To date, the Tianjin OE facility has delivered eight full nacelle sets – with one nacelle set consisting of two fan cowl bond panels and four longerons. The site’s immediate goal is to deliver 91 nacelle sets in 2015. It’s ultimate goal? Delivering 680 nacelle sets in 2018. What was the agenda for the Oct. 21 visit by Airbus Program Manager Benoit Letay and Supply Chain Quality Manager Lilian Tardieux? It included a “meet and greet” with the Tianjin OE management team and a plant tour, followed by reviews of the site’s cycle time and days to manufacture performance, quality standards, staffing plans and supply chain… among other things. When all was said and done, Airbus’ Letay had positive comments to share on several subjects. Waiting for the green light “As far as our capacity to ramp up, he noted that our cycle time is well measured, with evidence of detailed actions to improve,” explained Cossio. “Overall, he complimented our level of visual management on the shop floor and commented that the Tianjin OE team is fully engaged and waiting for the green light to ramp up. His final remark was a thank you for welcoming the Airbus representatives to our facility – he noted that the transparency provided was much appreciated.” The next day, during a visit to the nearby Airbus A320 FAL, it was Cossio’s turn to share some favorable impressions. “There was great application of the 5S tool at the Airbus FAL,” he said. “I was also impressed by the very low noise level and how well defined and controlled the one-piece product flow was. All in all, it was a good opportunity to meet our customer and build our relationship with them locally.” The day after the Airbus A320neo industrialization review at the Tianjin OE facility, several of the site’s employees seized the opportunity to visit the Airbus A320 Final Assembly Line (FAL) located 200 yards away. “It was a good opportunity to meet our customer and build our relationship with them locally,” noted Tianjin OE Industrial Transition & Operations Lead Paco Cossio. Pictured above in front of the FAL are (from left to right): Cossio; Airbus Supply Chain Quality Manager Lilian Tardieux, Tianjin OE General Manager SengLiang Goh, Aerostructures A320neo Fan Cowl PDT Lead Michael Winer; and Airbus Program Manager Benoit Letay. He added: “I’d like to express my thanks to all of the Tianjin team members that have been supporting A320neo fan cowl operations… as well as the Aerostructures A320neo program office, the bond panel transfer team, the Riverside R&D team and the Singapore R&D team. We’ve been successful in Tianjin because of the people – they are truly the most value asset we have in the company.” 5 “I will never set a limit on where I will end up” Capitalizing on opportunities to learn and grow have propelled these two Everett assemblers into leadership roles Offering employees challenging careers and opportunities to continually learn and grow is a key element of the “People” operating principle. Joseph Duff and Jason Whipple are prime examples of this principle in action. Both started as assemblers at the Everett inlet assembly and engine integration facility. Both are now team leaders. Skylines recently asked Joseph and Jason to discuss their career development journeys to date – including what attributes they believe contributed most heavily to their advancement and what lessons they learned from their previous bosses – both good and bad – that they are benefitting from now. Joseph runs the Rolls-Royce inlet production line and CNC machine operations at Everett, which encompasses a team of 15 operators, two Quality Assurance technicians, and one manufacturing engineer. Jason leads the GE inlet line, as well as the Paint Shop – a team consisting of 27 assemblers, three Paint Shop employees, two Quality Assurance technicians, and one manufacturing engineer. When you joined, did you have a leadership role in mind? Jason Whipple: It wasn’t my goal at first. But after working with the people here, it soon became one. We have an excellent team. I ran various crews in my previous job building homes, and everyone I work with here at Aerostructures is supportive and great to work with. I also like the challenge of leading efforts to streamline our processes. Joseph Duff: While I deeply enjoy building hardware, my long-term intent was to move up within the company into a leadership role. What are some of the attributes that you think helped you earn your promotion to team leader? Everett Team Leaders Joseph Duff (second from right in photo at left) and Jason Whipple (second from right in photo at right) both started as assemblers and have advanced into roles leading the facility’s Rolls-Royce and GE inlet production lines. Both are pictured above reviewing percent load visuals during daily Real-Time Problem Resolution gemba walks. “If there’s one thing I have taken away from both good bosses and bad bosses, it’s that the way you communicate is key,” said Duff. “While it may take a moment longer to explain the reasoning behind a decision, doing so will not only benefit the individual, but also the company. Someone that is led blindly will stop when you stop leading them, while someone that understands the bigger picture will carry on with self- motivation.” 6 “The actions you take, day in and day out, will greatly shape your future. While many things you do may seem to go unnoticed, if you have pride and passion for them, the ones your efforts matter the most to will notice.” Duff: A strong work ethic. I also believe in the Continuous Improvement tools that our company uses, am extremely organized and put 100% into everything I do. I also have taken – and will continue to take – every opportunity to learn more. Whipple: Hard work, an open mind, and the ability to learn from anyone. While some employees look to their leaders to develop them, others believe it’s the employee who owns his/her career progression. Which category do you fit in to? Whipple: No one thinks more about his/her career path than that particular person. You can’t expect your supervisor to spend the majority of his or her day thinking about you – they should only be there to support and guide you on the goals you have set and the decisions that you have made for yourself. Duff: The actions you take, day in and day out, will greatly shape your future. While many things you do may seem to go unnoticed, if you have pride and passion for them, the ones your efforts matter the most to will notice. I truly believe in the never-ending pursuit of knowledge. And while this is something you must seek out for yourself, the bosses I have had in the past have helped shape my future in one way or another. What have you learned from good bosses that you hope to emulate in your role? Whipple: I would say the most important lesson I have learned from previous bosses is the ability not to get caught up in one particular thing… to be able to take yourself out of the picture, step back, and look at the business as a whole and how your decisions affect everything down the line. It doesn’t matter if you save an hour now if it costs the business three down the road. What have you learned from bad bosses that you hope to avoid? Whipple: I have had supervisors in the past that were always negative about most everything – I believe that a positive attitude is a must if you want to lead a productive team. A positive attitude is as contagious as a negative one. Duff: If there’s one thing I have taken away from both good bosses and bad bosses, it’s that the way you communicate is key. While it may take a moment longer to explain the reasoning behind a decision, doing so will not only benefit the individual, but also the company. Someone that is led blindly will stop when you stop leading them, while someone that understands the bigger picture will carry on with self- motivation. What are your ultimate career goals? Duff: Just as I will never stop seeking to learn, I will never set a limit on where I will end up. Whipple: Anything is possible. You’ve been successful in advancing your careers. What advice do you have for your fellow employees seeking to advance theirs? Whipple: If possible, never turn down an opportunity to learn and grow. Duff: To quote Mahatma Gandhi: “Live as if you were to die tomorrow. Learn as if you were to live forever.” 7 “Gateway to the San Diego Bay” opens on the south side of the Aerostructures campus, signaling the beginning of the ambitious Bayfront Master Plan In what was called a “historic day for Chula Vista,” city and Port of San Diego officials officially opened the H Street extension connecting western Chula Vista neighborhoods with the San Diego Bay on Oct. 30. Completion of the palm tree-lined new road adjacent to the Aerostructures headquarters facility’s campus signals the beginning of the ambitious 550-acre Bayfront Master Plan. The development project will include hotels, homes, restaurants, shopping, and open space and parks. Speaking at the opening ceremony, outgoing Chula Vista Mayor Cheryl Cox noted the opening symbolized much more than just another stretch of concrete. “This is the only street in the city that now stretches from the foothills in the east to the bay,” she said. “It will be known as the gateway to the bayfront once development begins and the hotels and conference centers open their doors to visitors for the first time.” While the extension of H Street along the south side of the Aerostructures property is only about 2,000 feet long, it was still a complex undertaking. The $7.2 million project broke ground last November and was completed under budget and slightly ahead of schedule. Work included surface demolition of an area previously used by Aerostructures… with asphalt, concrete surfaces, utility pipes, storm drain pipes and structures removed. New utilities were installed, with a focus on the environment. Additions include a dewatering system and new bio-retention basins to aid in handling storm water runoff. Extension of the roadway also required construction of a modified four-lane roadway with a separate 12-foot wide bike lane and a five-foot wide sidewalk. Those additions should be welcome news to the many Chula Vista employees who take regular walks or runs to the bay as part of their workday wellness routines. Chula Vista Mayor Cheryl Cox spoke during the Oct. 30 opening of the H Street extension on the south side of the Aerostructures campus. The milestone represented another symbol of progress for the bayfront redevelopment project, which will include hotels, homes, restaurants, shopping, and open space and parks. San Diego Port Commissioner Ann Moore called the extension far more than a road project. “It’s an opening to San Diego Bay, making it significantly easier to access our beautiful Chula Vista bayfront,” she said. (Photo by Todd Delong) 8 Technical Support ACE site employees prove that preparing for an ACE Silver assessment can actually be fun When most employees think of the ACE operating system, “fun” is not normally the first word that comes to mind. But that’s not the case for the members of Aerostructures’ Technical Support ACE site. With its ACE Silver re-assessment approaching in the first quarter of 2015, Technical Support – which consists of the R&D-Business Development (BD), Military Programs and Manufacturing Support organizations – chose to prepare by having a little fun with the ACE tools. The forum was the Technical Support Site ACE Fair held last Thursday in Chula Vista. “The idea for putting on the ACE Fair came up while reviewing the ‘Leadership, Culture, and Environment’ section of the ACE workbook all sites use to drive their ACE progressions,” according to Michael Mastorakis, the ACE focal for the Manufacturing Support organization. “The goals were to drive a positive ACE culture and learn together as a site. Since we’re a ‘composite’ ACE Site, Manufacturing Support, R&D-BD, and Military Programs employees don’t get to interact with each other very often. But each organization has strengths that the other ones can learn from. The ACE Fair was an opportunity for learning together.” To establish a baseline for the event’s activities, Mastorakis and the Military Programs and R&D-BD ACE focals benchmarked against an ACE Fair the Finance group conducted last year. “With a rough idea of what each booth would consist of, we split into teams and made the booths our own,” Mastorakis said. “We wanted to design the activities so that anyone could participate and pick up the core concept of the ACE tools. We tried to make everything fun by keeping the activities simple and relatable.” Last week’s Technical Support Site ACE Fair was an opportunity for R&D-Business Development, Military Programs and Manufacturing Support employees to learn more about the ACE tools in preparation for an upcoming Silver re-assessment. One event activity was this detailed review of how the MFA tool works, presented by Military Programs ACE Focal Diana Carlson. Said one visitor to the “booth,” Theresa Wright, manager of Tool Accountability and Customer Property: “I liked the visuals and the presentation of this very detailed explanation of the MFA process. I learned some things about ACE I didn’t know before.” (Photo by Patrick Palmer) 9 Competitive spirit As an example, one activity centered on a mythical “ACE Bakery” receiving MFA scores from customers of less than 3 for its pumpkin pies. To address the situation, booth visitors were challenged to use Relentless Root Cause Analysis tools, such as the 5 Whys and Fishbone Cause-Effect diagrams, to get to the source of the low customer satisfaction levels. Another activity asked participants to help plan an effective and efficient Thanksgiving dinner by identifying process opportunities for adding value through a SIPOC (Suppliers, Inputs, Process, Outputs, Customers). The Fair agenda also included a Jeopardy-style quiz competition in which employees were presented with ACE-related general knowledge clues in the form of answers and had to phrase their responses in the form of questions. R&D Staff Stress Engineer Firdaus Khan found this activity particularly enjoyable. “I enjoyed being a participant in ACE Jeopardy and the competitive spirit displayed between R&D, Military, and Manufacturing Support,” she noted. “I was pleasantly surprised at the speed at which questions were answered. It made me realize that Tech Support really knows ACE and is quite passionate about it.” Learning a little more about ACE in fun and creative ways was the goal of the Nov. 6 Technical Support Site ACE Fair in the Chula Vista CI Center. Said Manufacturing Support Director J.C. Langlois (pictured above left) of the activity: “Our site is shooting for ACE Gold next year and continued performance improvement, so it’s important that we communicate and engage everyone in the ACE tools. I believe this activity and others like it will enable us to get to the next level in our ACE journey quicker.” (Photo by Patrick Palmer) Added Manufacturing Support Director J.C. Langlois, who kicked off the Fair with a presentation detailing the Technical Support site’s ACE journey and success to date: “Everyone was engaged and enjoyed the learning. In fact, some folks walking by the Fair and not part of our ACE site stopped, asked questions, and decided to stay and learn. The Fair enabled all Technical Support employees to learn and get more involved with all of our ACE tools, keeping us on the right path for improving the business day to day. And once we have our team using these tools as part of their day-to-day work, making it a habit, it will allow us to get to Gold much sooner. Our ACE focals have been preparing this for quite some time and executed the event flawlessly. My thanks to them in making this learning creative and fun!” 10 Members of Women in Aviation employee resource group find inspiration from pioneers who broke barriers The Women in Aviation employee resource group in Chula Vista launched just a few weeks ago with its introductory meeting, but already some of its members have an experience to be envied under their collective belts: meeting some of the pioneers of aviation. The occasion was the annual Hall of Fame Induction event held at the San Diego Air & Space Museum in Balboa Park. According to museum officials, the International Air & Space Hall of Fame commemorates those people throughout history and around the world, who have “made a significant difference and whose contributions are worthy of special recognition.” Past inductees include an eclectic group of aviation luminaries, ranging from 18th-century Swiss physicist Daniel Bernoulli – who developed the principle of fluid dynamics that enabled aircraft design – to modern-day entrepreneur Sir Richard Branson to Russian aviation pioneer Igor Sikorsky, whose namesake business is part of the UTC family. The museum’s Class of 2014 inductees consisted of an equally diverse group. Honorees included X-15 and space shuttle test pilot Joe Engle and Bill Boeing, Jr., the son of aviation pioneer and Boeing Company founder William Boeing, who was responsible for preserving the “red barn” – the first Boeing “site” and the oldest airplane manufacturing facility in the U.S. Also honored were a group and an industry pioneer that especially resonated with the Women in Aviation group attendees. Several members of Aerostructures newly formed Women in Aviation (WIA) employee resource group represented the company at the recent International Hall of Fame induction ceremony at the San Diego Air & Space Museum. The ceremony recognized several individuals and groups… and one lubricant. San Diego-based WD-40 was recognized for its first use by Convair to protect the outer skin – and, more importantly, the paper thin “balloon tanks” – of the Atlas missile from rust and corrosion. WIA members and supporters attending the ceremony included (left to right): Mychelle Nguyen; Niki Swisher; Ella Watson; Sara Crawford; Firdaus Khan; Michael Aten; Jennifer Davis; Heidi Chen; Joshua Pritekel; and Lin Liao. 11 “The highlight of the evening was learning about the honorees themselves. A standout was the ‘Ninety-Nines,’ an international fraternity of women pilots founded in the 1920s to promote aviation through education, scholarships and mutual support while honoring their unique history and sharing their passion for flight,” said R&D Staff Stress Engineer Firdaus Khan, head of the Women in Aviation employee resource group. “Another woman we learned about was Bessie Coleman, the first African American woman to earn a pilot’s license, who broke many barriers in aviation. Many of the recipients highlighted the importance of engaging the next generation to pursue STEM (Science, Technology, Engineering and Math) careers and to continue to keep America at the forefront of technology and innovation.” Foley employees seize chance to get flu shots, sample safety and health-related products at Wellness Fair More than half of the Foley facility’s workforce turned out for the site’s “Health & Wellness Fair” on Oct. 29. In addition to receiving flu shots and blood glucose/blood pressure/osteoporosis screenings, employees also had the opportunity to sample a variety of products from participating vendors. In the photo above, several Foley employees learn more about the safety glasses and gloves supplied by Safety Source, Inc. 12
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