Industry Forum

Rolls-Royce Inspection Planning Programme

Please note: This course is only open to supplier organisations who have been specifically invited by Rolls-Royce.

Course overview:   

This is part of the Rolls-Royce collaborative journey to drive out non-conformance on the journey to zero defects. Companies who should attend this course will be contacted by Rolls-Royce to request their involvement.

The course objective is to improve product verification planning, reduce inappropriate component measurement techniques, reduce the amount of MSA conducted, and minimis inspection by taking a fully risk-based approach to product verification. This course will demonstrate the potential for a reduced inspection workload and improvement in operational effectiveness.

The course will use live examples of best measurement practise. To reduce the impact on the working week, the training package uses a blend of self-study and instructor led training. The training package divided into four modules, combining a mixture of theory, worked examples and workshops.

Module 1 is self-study covering an overview of measurement. See Topics covered for details of the content of this module.
Module 2 is trainer delivered and covers Inspection Planning. See Topics covered for details of the content of this module.
Module 3 is trainer delivered and covers Optimisation, Reduced Inspection and Sample Inspection. See Topics covered for details of the content of this module.
Module 4 is self-study and covers CMM Programming strategies and is a mixed media format. See Topics covered for details of the content of this module.

Delegates are invited to bring a real component from your current Rolls-Royce portfolio to develop in the training. You will not be compelled to share information on your part with the other supplier delegates in the course.

Module 2 and 3 may be online (Covid and geographic restrictions given) or face to face. 

Feedback from previous sessions included the following. 
"We have a better understanding of the requirements and opportunity to apply reduced and sample inspection to our business.” 
"Mechanism to make the changes our business needs”. 
“Will reduce the queue and backlog in our inspection cell”.
“Not all classroom theory, really good practical hands-on experience to make real improvement”.

Who should attend:   

The training is aimed to improve the manufacturing package, and how product verification, inspection planning, and Measurement Systems Analysis is conducted. It is also intended to be the seed for improvement through the product portfolio so people with positions of influence should be considered. Therefore, the people who would benefit are those conducting these activities, typically this may be: 

Quality Manager 
Lead Programmer
Measurement Manager
Engineering Manager
Manufacturing Engineering
Inspection planning Engineer
Or other connected with Product Verification Planning and MSA

Benefits and Learning Objectives:   

  • Understand how the Characteristics matrix works and assists in planning and optimising inspection from the engineering specification (Drawing)
  • Understand how to make an inspection-plan and what needs to be considered.
  • The use of PFMEA to identify risks and control plans to reduce inspection.
  • Understand how to identify and prioritise opportunities in inspection improvement including Measurement Optimisation, Reduced inspection, Sample Inspection and Residual Inspection.
  • Understand the fundamentals of using CMM for the measurement of complex fabrications.
  • Understand how to review process capability and establish what measurements need MSA (Measurement Systems Analysis).

Topics covered:  

Module 1 - Measurement Overview – Self Study.

What is Measurement System Analysis (MSA)?
Why do we need MSA?
Consequences of poor measurement
When to conduct MSA?
Things to consider.
Rolls-Royce AS13003 MSA requirements
Managing suspect results
MSA read across
Future challenges

Module 2 - Inspection Planning – Trainer delivered.

What is an inspection plan?
Why do we complete inspection planning?
Consequences of incorrect inspection planning
Which standards apply?
Steps to implement inspection planning.
How to complete a characteristics matrix
Rolls-Royce Gauge guide
Inspection planning device selection decision flow chart

Module 3 - Reduced and sample inspection – Trainer delivered.

Inspection journey
Top level strategy
Steps to identify opportunities for improvement.
Requirement for improvement
Basis for approval
Review of current state
Product functional requirements and risks 
Feature categorisation
Agree verification method.
Document verification method
Process steps
Measurement control plan
Which standard applies?
Correct path for the part
Formed features.
Reduced inspection.
Sample inspection
Residual inspection
Authorisation process
Further information

Module 4 – CMM Programming Strategies – Self Study.

Edge point measurement
Plane creation
Circle element measurement
Plain diameters and holes
Hole measurement direction and start point.
Tapped holes.
Length measurement
Chamfers and cones 
Wall thickness
Radii and partial arcs

Introduction to IF

We have been delivering significant and measurable performance improvements for leading global manufacturers for more than 25 years and believe there is no one size fits all approach to driving competitiveness across the industry. Toyota, Rolls Royce and Electrolux are among the brands who have tapped into our expertise to ensure they remain on top in their own fiercely competitive markets.

Why choose Industry Forum:   

Industry Forum helps major global manufacturers understand, optimise and improve both manufacturing capability and business performance.

An integrated team of consultants and practitioners – all seasoned expert engineers with multi-sector manufacturing experience – Industry Forum brings together a world-class combination of improvement competency, insight, process and best practice.

Spanning automotive, aerospace, consumer appliance, electronics and food sectors, for over 20 years Industry Forum has planned and delivered some of the world’s most consistent and successful transformations for business-critical manufacturing operations.

Our trainers are expert practitioners with hands-on industrial experience and highly developed communication skills.

They have a wealth of technical expertise and often provide on-site advice and coaching. During every course we will encourage collaboration and sharing of practical experiences, ensuring learning can be put into context and empowering delegates to apply their new skills successfully in their workplace as well as making sustainable improvements.

Training can be offered either through open courses or in-house to suit the customer requirements.

Course booking details:   

This course is a blended programme of instructor led training and self study.

Please note that the following dates will only run subject to sufficient bookings being received.

Leading Expertise
We don’t employ “trainers”, rather a team of experienced industry experts who are able to apply their knowledge to your business

Proven Capability
We have been helping organisations like yours for over 25 years to deliver and maintain sustainable improvement

Attainable Results
We know what’s possible and how to help you achieve it by utilising our tried and tested techniques for long term success

Robust Execution
We believe that training should be through a ‘learn by doing’ approach with coaching and mentoring wherever possible

No available dates for this course at present. Please fill in the form below to register your interest.

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