© Vibro-Meter Confidential.. GP7200 Project © Vibro-Meter Confidential. GP7200 Project.


GP7200 Project


GP7200 Program OverviewGP7200 Program Overview• Definition of the project Team :

– GP7200 MAV Team :• Chris Tose : PM• Andy Watt : SyE• Mark Twain : SwE• Jim Phillips / Leo Madden : HwE

– GP7200 VMSA Team :• Markus Pfaffendorf : PM• Claude Vicidomini : TL & SyE• Fabien Hue : HwE• Christophe Blouët : SwE• Béat Mauron : TSE

PM : Project ManagerTL : Team LeaderSyE : System EngineerHwE : Hardware EngineerSwE : Software EngineerTSE : Test System Engineer


VMSA Team Organisation

Team Leader

C. Vicidomini

Engineering

Chief Engineer

J.Kuenlin

Systems Engineering

C.Vicidomini

Quality Assurance

P.McCann VMSA

Manufacturing

J. Rossier

Purchasing

O. Laurenza

Component Engineering

A. Mozerski

Customer Support

C. Milan

Commercial Manager

VMSA

C.Tose- VMSA/MAV UK

Vibro-Meter SATeam

M.Pfaffendorf

Root Cause/ Industrialization

Y. Conti


Mav UK – GP7200 Hardware and Software

Engineering Manager

Richard Johnson

Quality Assurance

Paul Brooker

Software Engineering

Mark Blay

Mechanical Engineering

Kenny Deans

Configuration / Data Management

Kenny Deans

HardwareEngineering

Leo MaddenJim Phillips

VSMProjectLead

C.Tose

System Engineer

Andrew Watt


Level 1 : Transfer Plan

Jan Feb

2007 2008Mar Apr May Jun Jul Jan Feb Mar Apr May Jun JulAug Sep Oct Nov Dec

P04 Manufacture

P04 Qual TestingP05 RDGT

Engine Cert Software Software Support/Problem Reports

P04 ATP

Survey Phase

PIL Engine Cert

STS Qual

AFDX SW

Qual Reports

SW Update

SW Cert Docs SW Cert Docs

Software Support/Problem Reports

SW Update SW Update SW Update

HW Re-spin (P05) P05 Qual Testing

PM

SOI-1 Review

Final SW Cert Reports

HALT


Achievements This Period Planned Activities/Problems Solved

Escalation/Help Required Obstacles/New Problems

1. AFDX software: RI, SYSGO and VMSA integration session in RI week of 15th Jan

2. PIL Rig software delivery to GE3. Completion of DAT Vibe endurance tests4. Completion of DAT Shock test5. Integration of HSESB into ATP

1. Intermittent CAN failure during Radial vibration endurance tests. This has created a 3 day DAT schedule slip

1. ARINC-664V AIM board integrated into VMSA GTS

2. ATP software update completed including HSESB and enhanced BIT testing

3. DAT Vibration endurance tests completed 2 axis with no failure

4. Breakthrough in AFDX SYSGO/Meggitt integration problems

1. Greenhills certification schedule? This depends on Greenhills responsiveness to Meggitt`s request for a pull.

GENx Status Report Progress

Problems


P03 Delivery status

SER Status DeliveryVBR001AA At GE CompleteVBR003AA At GE CompleteVBR004AA At GE CompleteVBR005AA At GE CompleteVBR006AA At GE CompleteVBR007AA Assembly Complete 19th Jan 07VBR008AA Assembly Complete 26th Jan 07VBR009AA Assembly CompleteVBR010AA In BuildVBR011AA In BuildVBR013AA In BuildVBR014AA Build planned 15th JanVBR015AA Build planned 15th JanVBR016AA Build planned 15th JanVBR017AA Build planned 15th JanVBR018AA Build planned 15th JanVBR019AA Build planned 15th Jan

Room Temp ATP completeRoom Temp ATP complete

CommentsP03AB unit to be returned for upgrade to P03AA

Room Temp ATP completeAwaiting VSM and CPM Modules (due 20th Jan 07)Awaiting VSM and CPM Modules (due 20th Jan 07)Awaiting VSM and CPM Modules (due 20th Jan 07)


P03 Delivery slippage and current status

Original shipment date of mid Sep 06 slipped to mid Nov 06 Risks were identified relating to Software/Test system/hardware integration activities but

these were underestimated Delay and delivery blockage caused by Software migration/integration onto 5554

platform Delays not due to lack of material All production test activities transferred from NH to VMSA in Sep 06 ESS screening procedure and equipment took longer to implement than planned

Current status Flow of material and finished parts from manufacturing is on plan 3 units complete and 9 further units in the pipeline (materials confirmed) Bottleneck and risk area is ESS (Temp and Vibe)

• P03 units are being subjected to temperature testing beyond the current design capability. This has/will continue to cause yield problems

• Only 1 unit can pass through ESS at a time (equipment constraints)• ESS system to pass 5 units at a time is planned for Q3/2007• Current weekly shipping capacity is 1 per week (ESS) and assuming no ESS failures


AFDX – Steering Plan

Aug NovOctSep Dec Jan Feb Mar Apr2006 2007

JunMay

EmbVUE

SYSGOKick-off

AFDX stackwithout EDE

Time Manager Final Cert package

SYSGOofficiallyselected

Jul

deliveries to GE

SepAug Oct

Phase 3Formal testing & Certification

Phase 2Develop Boeing extensions

Phase 1Porting A664 stack

System integration

updatewith EDE Time

Manager

AFDX Stack integrationon CPM

Target HWdelivered to Sysgo

Acceptance tests

SW

up

date

BasicA664 AFDX

stack

AFDX Stack integrationfor ATP and DAT tests

As a minimum, basic A664

transmission

SW

up

date

ICD / API issues

Full EDE (see Note2)

Full BIT (see Note3)

SW

up

date

Draft Cert package


DAT Status

DAT testing as per VMSA document STS-1997-01

Test STS-1997 Ref Test Schedule CommentPin Injection Transient Susceptibility Para 5.6 Test Complete PASSPower Input Para 5.7 Test Complete PASSExplosion Proofness Para 5.8 Test Complete PASS

Vibration Para 5.2 23 Dec to 11th Jan 07

Unit has completed Axial and Tangential endurance tests. CAN bus failure after 3 hours in radial testing - suspect connector intermittent. This is in investigation

Shock Para 5.3 15th Jan 07 Slipped due to radial vibration problemThermal Cycling Para 5.4 17th Jan to 26th Jan

Humidity Para 5.5 29th Jan to 9 Feb 072nd unit has been sourced to pull this forward

Identified Risk: Planned dates exclude Failure investigation and root cause


Qualification Tests ScheduleTest Test Location Proposed Test Date

Test Unit Number

5. VibrationVibro-Meter SA, Fribourg Switzerland

26th Mar 07 to 10th Apr 07 1

6. ImpactVibro-Meter SA, Fribourg Switzerland

12th Apr 07 to 13th Apr 07 1

8. Sand and Dust

RUAGAllmendstrasse 86CH 3602 ThunSwitzerland

23rd Apr 07 to 24th Apr 07 2

10. Salt SprayVibro-Meter SA, Fribourg Switzerland

26th Apr 07 to 1st May 07 2

15. Thermal CycleVibro-Meter SA, Fribourg Switzerland

12th Mar 07 to 16th Mar 07 1

16. Explosion ProofnessCentre d’Essais des PropulseursOrsay, France

3rd May 07 to 4th May 07

3 (Chassis Only)To be

rescheduled to April 07

17. HumidityVibro-Meter SA, Fribourg Switzerland

16th Apr 07 to 2nd May 07 1

18. WaterproofnessVibro-Meter SA, Fribourg Switzerland

19th Mar 07 to 21st Mar 07 1

19. Pin InjectionEmitech, Montigny le Bretonneux, France


20. Power InputVibro-Meter SA, Fribourg Switzerland



Software Certification Status

Preliminary set of plans provided to GE in Sep 06

Follow-up SOI-1 review to be held at VMI, NH mid Feb 07

SYSGO plans provided and are in VMSA review loop. These will be submitted prior to the SOI-1 review

GreenHills plans received 2 Jan 07

Certification liaison role will be handled by Chris Tose

Identified Software certification schedule risks Current SYSGO plan for final certification documents is end June 2007

• Negotiation started with SYSGO to bring this date forward Current GreenHills plan for final certification documents is Sep 2007

• This will need escalation within Meggitt perhaps with GE support


SDRL Status

Deliverable dates to be jointly reviewed to ensure compatibility with GE program

Microsoft Excel Worksheet


Status of open DDR ChitsChit Title Status Planned

for

#1 Heaters Heater circuits will be depopulated. Components will be up screened. CM235 has been raised.

P04

#2 Connector Chassis Interface

New Design proposed which gives direct metal to metal contact. Initial bonding measurements of new design are not in spec.Alternative design approaches are being reviewed.

Assembly drawings provided to GE for review meeting.

P05

#3 Chassis corrosion Protection

ROM submitted for Alodine 1A chassis with Painted Feet. CM236 has been raised

P04

#4 Flex Chaffing

Initial proposed redesign of flexes rejected during internal design review. Alternative assembly strategy with modified flexes being assessed.

P05


Product Development Strategy Proposed (P03 to P05 Evolution)

P03 P04 P05 P06

Jan 07

DAT Std

Beg Mar 07

Cert Std

Q3 07

1st Flight Std

???

EIS Std

EDPPILDAT(FTB?)

CertHalt1St Flight?

1st FlightRDGT

EIS

Drain holes

PSU Updates

Up-screened Parts

Surface Finish

Bond strap (Nickel)

Flexes

Connector Bonding

VSM Mods (VRT / Strain)

DAT Updates?

Bigger Box & CPM

Cast Box

RGDT

HALT

May need to combine P05 & P06 into one configuration, depending on availability of System EMI test


Larger Box and CPM

Why a larger box? The existing P03/P04 chassis provides ZERO growth contingency on the CPM module

• We have no mitigation if future changes are required due to DAT, CERT, HALT problems, Component obsolesence or functional enhancements

Increase in CPM real estate will allow implementation of enhanced automatic testing Improvement of Flexes is restricted due to insufficient space at front/rear backplanes

Draft outline drawing supplied separatley60mm (2.36 inch) extension in chassis length allocated as follows

30mm (1.18 inch) extension to CPM module 30mm (1.18inch) to improve flex routing/standoffs Extension of VSM not envisaged but further discussion required

Estimated weight increase of 700g (1.54lbs)Lead time of extruded box (proto) 6 weeksLead time for Casted box 4 monthsLead time of CPM approx 6 months


Post P04 (Cert Baseline) Change/Impact/Assessment

Change Impact (S/M/H) Re-Test GE Impact

Flexes Vibe None

Electrical Bonding Bonding/Vibe None

VSM (VRT / Strain) EMI / Thermal

Pin Injection

EMI / Lightning?

Bigger Box Vibe / Thermal

Shock/Impact?

FBO?

Cast Box None (Analysis)

Shock/Impact?

Salt spray?

None

Bigger CPM Vibe / Thermal / EMI

EMI

Bigger VSM? Vibe / Thermal / EMI


P05 Certification Test Matrix

Certification strategy for P05 will be jointly worked with GE using the attached 25 point matrix

Microsoft Excel Worksheet


Production Yield

Based on P03AA data Nov 06 to dateBatch #1 – 6 Units 4 units passed full ESS screening and have been delivered to GE 1 unit failed at 75Degrees C 1 unit supplied on loan (no ESS) Yield of 80%

Batch #2 – 4 units 4 units from 4 passed room temp ATP at first pass Units now due into ESS

Batch #3 Scheduled to start 15th Jan 07


Ball Grid Array soldering process

A BGA repair station is already set up within VMSA manufacturing.

The GENx EMU is the fifth product using Ball Grid arrays

Non GENx products are already being repaired and reworked

The rework process is still to be formalised

© Vibro-Meter Confidential.. GP7200 Project © Vibro-Meter Confidential. GP7200 Project.

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