Compressor Test First Pass Yield Improvement

Abstract

This project was executed within a commercial aerospace maintenance and overhaul facility to enhance compressor overhaul performance by improving First Pass Yield (FPY) and Rolled Throughput Yield (RTY), by employing the DMAIC methodology. The SMART framework was applied during the Define phase to establish clear, measurable, and achievable objectives aligned with the improvement cycle. The team identified key inefficiencies related to equipment calibration, non standardized troubleshooting, and productivity variation between shifts. Data from the Measure and Analyze phases indicated that five defect categories accounted for 80% of test failures, with imbalanced equipment calibration as the dominant cause. Implemented improvements included equipment recalibration, standardized troubleshooting protocols, pre-assembly inspections, and cross-training initiatives. Preliminary outcomes demonstrated FPY improvement to 50%, with reductions in three of the five primary failure modes, while ongoing monitoring under the Control and Sustainment phase will assess long-term stability, verify training efficacy, and monitor continued yield enhancement.