W. Harris, Sikorsky Aircraft, Stratford, CT; J. D. Tirpak, Advanced Technology Institute, North Charleston, SC; D. Gearing, Industrial Capabilities Division, Fort Belvoir, VA
Introduction PROFORGE is the name for a cross-functional, cross-departmental procurement led team that has re-engineered the way that we design and acquire forgings. Directly supported by the Forging Defense Manufacturing Consortium, and partnered with the Advanced Technology Institute, the PROFORGE Team has participated in lean events, benchmarking activities, training seminars, and on product/process improvement activities which have led to reductions in lead times and costs for this strategic material form. While science and technology have been an element of the team’s activities, the most significant advances have occurred by increased communication and cooperation internally between departments and externally between customers and suppliers in an integrated value-stream approach. PROFORGE – Teamed Supply Network Management at Sikorsky The Sikorsky PROFORGE Team has been in existence since June 2003. This team, sponsored by the senior management of Purchasing and Research & Engineering departments, has promoted partnerships and collaborations with Sikorsky forging suppliers to improve cost and lead-time as well as responsiveness and customer satisfaction. Tangible savings to the UH60M program and the Defense Logistics Agency have exceeded the initial investment in resources. In addition to these “hard” savings, Sikorsky has realized many so-called “soft” benefits, especially during the product development process. As strategic materials such as titanium become increasingly difficult to obtain, the PROFORGE Team has been instrumental in supplier down selection, tooling procurement, and material aquisition concurrent with design development. The team has tackled quality issues, using simulation technology to understand root causes and test corrective measures. Additionally, the team is working with suppliers to promote the use of forging and heat treatment simulation to optimize processes prior to insertion on the production floor. Summary This paper describes how Sikorsky has grasped the power of cross-functional chartered teams in working enterprise issues with complex business and technical requirements.
Summary: PROFORGE is the name for a cross-functional team that has re-engineered the process for design and aquisition of forgings. This paper describes how increased internal and external communication and cooperation have promoted technilogical excellence.