g GE Power Systems

GasTurbine Bearings Module - 2B18A

Project #: H56619.1
Phase: DMAIC
Date: 3 /14 /02
Green Belt: Denise Palumbo
g Project Summary GE Power Systems

Project Team
Project Title: Project Status: Complete

Staff Champion: Chrimes, Ted Start Date:3 /14 / 02

Champion: Chamberlin, Matt
Master Black Belt::LaChapelle, Mike Expected Completion Date:6 /1 / 02
Project Leader: Palumbo, Denise
Mentor:Vaupel, Matt Actual Completion Date:6 / 1/ 02

Role Phone Comment

Vaupel, Matt Black Belt 8*235-2102 Mentor

Palumbo, Denise Green Belt 8*235-5166 Project
Leader
g Project Summary - Define GE Power Systems

PROBLEM STATEMENT
The Gas Turbine Bearings Training Module, 2B18A is not complete such that a
qualified Trainer/Instructor can it to easily and effectively train new Field Engineers
on these critical turbine components vital to reliable unit operation which in turn
will deliver satisfaction to the customers who buy GE products .
GOAL
Measure and control the quality and effectiveness of the Gas Turbine Bearings
Module to provide complete, accurate and precise training and also provide
performance feedback on students participating in the program.
BUSINESS IMPACT
A well developed and defined training program will provide our business with
marketable Field Engineers who will have the necessary tools to locate and interpret
drawing and technical information provided with G.E.Gas Turbines and be able to
use this information effectively to supervise and execute gas turbine installation,
start up, and maintenance activities on equipment at GE customers sites.
IDENTIFY CUSTOMER WANT
A Field Engineer who can provide to our customers:
A quality job
Done correctly
On schedule
g Project Summary - Measure GE Power Systems

Lesson Module Quality Selected as CTQ

METRIC- Using a Material Quality Check Sheet (MQCS) the rating for each applicable
tab was calculated. The final module will be in a digital format, referencing
a 7FA Gas Turbine. For the Gas Turbine Bearings Module, 2B18A, ther are
9 tabs that should be 7 points each one. (please reference MQCS)

DEFECT - any value shown as less than a 7 on the MQCS is defined as a defect.

OPPORTUNITY- Each tab presents an opportunity for a defect.

g Project Summary - Measure GE Power Systems

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Lesson Modules are the back bone of all training!!!

g Project Summary - Measure GE Power Systems

Process Map
Start with original module? Are Materials Available? NO
Instructor Requires Preparation Time
(Stage 1)

YES
Research Topic
NO
Are Materials Useful?
Instructor to generate a topic outline
YES
NO
Is research outline acceptable?

YES
Generate Materials Using MQCS As Guide

Review With Coordinator

YES

NO
Are materials generated acceptable?
(stage 2)

Create module CD
NO (stage 3)

Are Business & Student

Instruct Class
Feed Back Positive?
Control Loop

Stop
g Project Summary - Analyze GE Power Systems
Ratings System
Rating Description
0 No Materials Exist
1 Existing Materials are Totally Obsolete.
2 Existing Material is incomplete, the content is poor and some materials are obsolete.
3 Existing material is incomplete, the content is poor and has no structure.
4 Existing material requires structure, content is poor.
5 Existing Materials content is acceptable but needs structure.
6 Existing Content is good but no digital copy (file) or needs minor repairs
7 Existing Content - Ready for Review
Stage 1 Status of the tab how was found it
Stage 2 Material is on digital format ready to be use
Stage 3 Material is on CD format
99 Does Not Apply

Note on Review Process:

Determine who is a subject matter expect (SME) for the module. A SME shall be used to review and sign off on a module. Use Stages 1,2 and 3 to indicate how far along review
process is at any given moment.

Binder Contents: 2B18A Gas Turbine Bearings

Stage Stage Stage 3
ab # Description Rating 1 2
Introduction to Instructor 0 0 0
2 Learning Objectives 0 7 0
3 Outline and Agenda 0 0 0
4 Lesson Plan 0 0 0
5 Presentation Materials 3 3 3
6 Hand Outs - Workmats, any supplemental information given out in class. 99 99 99
7 Quizzes and Exams 0 0 0
8 Keys for Quizzes and Exams 0 0 0
9 Homework 99 99 99
10 Keys for Homework 99 99 99
11 Lab Guidelines for the Instructor 99 99 99
12 Lab Set Up 99 99 99
13 Lab Equipment 99 99 99
14 Lab Procedure (Student Information) 99 99 99
15 References (Instructors) 0 5 5
16 References (Student) - GEKs, Hardcopy of Presentation, Procedures, etc. 0 5 5
17
18
g Project Summary - Analyze GE Power Systems

Long
Product/CEO/ Term
Process Defects Unit Opt Total Opt DPU DPO DPMO Shift Capabilit Sigma
D U OP TOP DPU DPO DPMO Shift Sigma-L Z.B
GT Bearings Before 9 1 9 9 9.0000 1.000000 1000000 1.5 -2.52 -1.02
GT Bearings Goal 0 1 9 9 0.0000 0.000000 0 1.5 1.45 2.95
1.5
1.5
1.5

Grand Total 9 18 0.500000 500000 1.5 0.00 1.50

Input Fields
D Total Number of Defects
U Total Number of Units
OP Number of Opportunities
Shift Sigma Shift (Default: 1.5)

Calculated Fields
TOP U*OP
DPU D/U
DPO D/TOP = D/(U*OP)
DPMO DPO * 1000000
Sigma-L White Book 11.10
Z.B. (Sigma-L)+Shift version 2.0
g Project Summary - Analyze GE Power Systems

90% DEFECT REDUCTION GOAL

Pre Lesson Module 1,000,000 DPMO 2.95 Sigma

Post Lesson Module Goal 100,000 DPMO 2.95 Sigma

g Project Summary - Improve GE Power Systems

Object -To evaluate the Gas Turbine Bearings Module

2B18A for existence and completeness of individual
Module tabs.

Action Taken to Determine Improvement - Used the

Module Quality Check Sheet(MQCS) to evaluate the
contents of the Gas Turbine BearingsModule 2B18A in the
Gas Turbine Technology Program.

Deliverable - An updated accurate, and usable module

lesson plan in both hard copy and CD format for use in the
Gas Turbine Technology Internal Training program.
g Project Summary - Improve GE Power Systems

Measurement of Improved GT Bearings Module 2B18A

Content via L1 Spreadsheet
Long Term
Product/CEO/Process Defects Unit Opt Total Opt DPU DPO DPMO Shift Capability Sigma
D U OP TOP DPU DPO DPMO Shift Sigma-L Z.B
GT Bearings Before 9 1 9 9 9.0000 1.000000 1000000 1.5 -2.52 -1.02
1.5
GT Bearings After 0 1 9 9 0.0000 0.000000 0 1.5 1.45 2.95
1.5
1.5

Grand Total 9 18 0.500000 500000 1.5 0.00 1.50

Input Fields
D Total Number of Defects
U Total Number of Units
OP Number of Opportunities
Shift Sigma Shift (Default: 1.5)

Calculated Fields
TOP U*OP
DPU D/U
DPO D/TOP = D/(U*OP)
DPMO DPO * 1000000
Sigma-LWhite Book 11.10
Z.B. (Sigma-L)+Shift version 2.0

100% Reduction in Defects!

g Project Summary - Control GE Power Systems

Procedure
Annual audit of the Gas Turbine Bearings
Module, 2B18A, tab contents against the
MQCS criteria.
Metric
Existence of required materials in module
tabs, timeliness and current applicability of
the materials.
Owner
The Gas Turbine Technology Program
Coordinator