AEROSPACE QUALITY MANAGEMENT SYSTEM

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AEROSPACE

QUALITY MANAGEMENT

SYSTEM

-

_-

9100

₉₁₀₀

Dale K. Gordon

Rolls

-

Royce North America

Past Chairman

Americas Aerospace Quality Group

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Aerospace Quality Standards

Numbering System

•

• International Standards

International Standards

-

91xx

–

– Are planned for harmonization across all 3 aerospace Are planned for harmonization across all 3 aerospace sectors and are recognized globally

sectors and are recognized globally

•

• Americas Standards

Americas Standards

-

90xx

–

– Are published for use by AAQG, may become an Are published for use by AAQG, may become an 91XX standard at a later date

91XX standard at a later date

•

• “

“

AS

”

Standards

-

Americas

–

– Published by Society of Automotive EngineersPublished by Society of Automotive Engineers

•

• “

“

EN

”

Standards

-

Europe

–

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Aerospace Quality System

Standards

•

• INTERNATIONAL STANDARDS

INTERNATIONAL STANDARDS

–

– 9100 9100 -- Quality System for Aerospace Quality System for Aerospace Manufacturers

Manufacturers

–

– 9101 9101 -- ChecksheetChecksheet for 9100for 9100 –

– 9102 9102 -- First Article InspectionFirst Article Inspection –

– 9103 9103 -- Management of Key CharacteristicsManagement of Key Characteristics –

– 9110 9110 -- Quality System for Aerospace Repair Quality System for Aerospace Repair Stations

Stations

–

– 9111 9111 -- ChecksheetChecksheet for 9110for 9110 –

– 9120 9120 -- Quality System for Quality System for ““PassPass--ThroughThrough”” Distributors

Distributors

–

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Tier 4

Tier 4--Make to Print / Machine Shops/ Make to Print / Machine Shops/ Processors Processors Tier 2 Tier 2 Integrators / Integrators / Source Control/ Source Control/ Software Dev./ Software Dev./ Major Assemblies Major Assemblies Tier 5

Tier 5--Distributors (Fasteners, Raw Materials,Distributors (Fasteners, Raw Materials, Commodities, Adhesives, Special Materials)

Commodities, Adhesives, Special Materials)

Tier 3

Tier 3--Integrators /Integrators / Source Control / Specialty

Source Control / Specialty

Electronics / Wiring / Compnts

Tier 6

Tier 6--Raw Materials (Castings, Forgings, Sheet, etc)Raw Materials (Castings, Forgings, Sheet, etc)

Aerospace Supply Chain

Tier 1 Tier 1

Spec ial P

roce sses

Spec ial P

roce sses Com pany Spe cific Com pany Spe cific

or N ADCA

P or N

ADCA P 9100 9100 9120 9120 9003 9003 Tier 1 Tier 1

Vehicle / Airframe / Vehicle / Airframe / Propulsion Manufacture

Propulsion Manufacture Var

iatio n R edu ctio_n Var iatio n R edu ctio_n 910₂ 910₂ 910₃ 910₃

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ISO TC20

-

WG11

ISO Technical Committee 20

ISO Technical Committee 20 -- Aircraft & Space VehiclesAircraft & Space Vehicles

–

Established Working Group 11 (April 1997)

•

• Chartered to develop and publish an international Chartered to develop and publish an international quality system standard based upon ISO 9001 for

quality system standard based upon ISO 9001 for

the aerospace industry

•

• United States (Gene Barker) ConvenerUnited States (Gene Barker) Convener •

• Members:Members: Brazil

Brazil ChinaChina FranceFrance Germany

Germany JapanJapan MexicoMexico United Kingdom

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ISO TC 20

WG11

AS9100

_{EN 9100}

AS9000

_{prEN 9000-1}

Americas

Standard European

Standard

ISO 9001

1994

World Aerospace Quality

Standard ; AS/EN/JIS Q 9100

International Quality System

Standard Creation 1998

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Aerospace Quality System

Model

C o m p a n y R e q m n t s AS/EN/ JIS Q 9100 Int’l Reqmnts & Company Reqmnts

Internationally Agreed Implementation Processes

Risk Mgnt Prgrm Mgnt Special Process Process Rqmts Deliver able Non-Deliver MRO 9110 Dist. 9120 Service Specific Requirements

Quality System Requirements - International

Standard ISO 9001

Common Aerospace Quality System Requirements -

International Requirements 9100

Program Specific Requirements Hardware Specific Requirements Software Specific Requirements

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Why 9100?

•

• To standardize Aerospace quality

To standardize Aerospace quality

expectations on a

global

level

•

• To achieve improvements in quality and

To achieve improvements in quality and

reduce

costs

throughout the value stream

•

• ISO 9000 model for quality does not

ISO 9000 model for quality does not

capture

regulatory requirements or

importance of safety, reliability or

maintainability

•

• Captures aerospace

Captures aerospace

supplements

agreed

to at an international level

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ISO9001 versus AS9100

•

• AS 9100 version is formatted to match ISO 9001:2000 and AS 9100 version is formatted to match ISO 9001:2000 and added “requirements” that provide for

added “requirements” that provide for -

-•

• Regulatory organizations interfacesRegulatory organizations interfaces •

• Configuration ManagementConfiguration Management •

• Design and Development V& V., & V&V testingDesign and Development V& V., & V&V testing •

• Control of changes in Production ProcessControl of changes in Production Process •

• Control of production equipment, tools, NC machinesControl of production equipment, tools, NC machines •

• Control of work in outside facilitiesControl of work in outside facilities •

• Control of service operationsControl of service operations •

• First Article InspectionFirst Article Inspection •

• Inspection documentationInspection documentation

•

• These added requirements enables a standardized These added requirements enables a standardized approach to supplier flow down requirements

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Year 2000 ISO 9000 Revisions

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ISO 9001:2000 / 9100:2001

Timeline

DEC. 2003

ISO 9001:1994

2000 2001 2002 2003

ISO 9001:2000

9100 : 1999 _{9100 : 2001}

9100A:2001 includes both ISO 9001:1994 and ISO 9001:2000 models until December 2003

9100:2003 ?

Note: AS9000 / AS9100 section 2 phase out December 15, 2003

Certificates are expected to expire in line with ISO 9001 requirements Does NOT mean that “approvals” are invalid

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FAA Endorsement of

AS9100:2001

“

“The Aircraft Certification Service still believes that the effecThe Aircraft Certification Service still believes that the effective tive implementation of AS9100

implementation of AS9100 -- Rev A will continue to enhance an Rev A will continue to enhance an organization

organization’’s overall performance. The statement found in s overall performance. The statement found in Section 1.1 General: states

Section 1.1 General: states ““It is emphasized that the quality It is emphasized that the quality management system requirements specified in the standard are

management system requirements specified in the standard are

complementary (not alternative) to the contractual and applicabl

complementary (not alternative) to the contractual and applicable e law and regulatory requirements.

law and regulatory requirements.”” is still a requirement that must is still a requirement that must be adhered to.

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Current USA

DoD

Position

•

• Proposed Department of Defense (Proposed Department of Defense (DoDDoD) Adoption of the ) Adoption of the AS9100:2001 Quality Management Systems

AS9100:2001 Quality Management Systems -- Aerospace Aerospace - -Requirements (Nov. 2001)

Requirements (Nov. 2001)

–

– prepared ...prepared ... DoDDoD adoption notice for the AS 9100:2001 to adoption notice for the AS 9100:2001 to provide information for document visibility and facilitate

provide information for document visibility and facilitate

document availability to

document availability to DoDDoD personnel.personnel.

•

• International Aerospace Quality Standard AS 9100, 2001 edition, International Aerospace Quality Standard AS 9100, 2001 edition,

Quality Management Systems

Quality Management Systems----Aerospace Requirements,Aerospace Requirements, was was adopted on March 1, 2002 for use by the Department of Defense

adopted on March 1, 2002 for use by the Department of Defense

(

(DoDDoD). The standard specifies additional requirements ). The standard specifies additional requirements identified by the aerospace industry specifically for an

identified by the aerospace industry specifically for an

aerospace quality management system based on ISO

9001:2000

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Current NASA Position

on 9100

•

• NASA issued Adoption notice on April 8th

NASA issued Adoption notice on April 8th

2002, signed by Dr. Michael Greenfield,

Associate Administrator for Mission and

Safety Assurance.

•

• This notice makes AS9100A available for

This notice makes AS9100A available for

use by NASA for procurements for all

programs.

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SPACE CONSIDERATIONS

•

• ISO TC20 / SC14 and IAQG have

ISO TC20 / SC14 and IAQG have

on

-

going project to supplement

9100 w/ special considerations for

Space needs

–

– Includes Risk Management & Safety and Mission Includes Risk Management & Safety and Mission Assurance emphasis

Assurance emphasis

–

– Use as supplement to 9100Use as supplement to 9100 –

– Consideration for full inclusion at next revision of Consideration for full inclusion at next revision of 9100

9100

•

• Other industries / applications are considering using Other industries / applications are considering using 9100

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9100

Checklist

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9101

•

• IAQG developed 9101 Common Checklist to

IAQG developed 9101 Common Checklist to

be used by industry to cover all ISO 9001 &

9100 elements

-

allows industry to share

audit information

•

• Must be used by Certification Bodies when

Must be used by Certification Bodies when

performing 9100 audits

•

• Scoring feature is currently

Scoring feature is currently

used by many organizations

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9110

Repair Station Quality

System

•

• Status of 9110

Status of 9110

–

– New version was developed with ManufacturersNew version was developed with Manufacturers--MRO, MRO, DoD, FAA and Airline inputs

DoD, FAA and Airline inputs

•

• Takes latest version of FAA Part 145 into accountTakes latest version of FAA Part 145 into account

–

– Will replace EN 9110 in Europe that is already in use Will replace EN 9110 in Europe that is already in use since 1999

since 1999

•

• 3 Airlines and most European Manufacturers 3 Airlines and most European Manufacturers already use it to specify requirements to MRO already use it to specify requirements to MRO suppliers

suppliers

Registration / Certification plans being put in place

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9110

Repair Station Quality

System

•

• Why 9110?

Why 9110?

–

– Manufacturers want a Quality System flowManufacturers want a Quality System flow--down down requirement for their repair activity

requirement for their repair activity

–

– Manufacturers want reputable suppliers that have Manufacturers want reputable suppliers that have repair station approvals and a defined quality

repair station approvals and a defined quality

system

–

– There is a need to put all of the expectations in There is a need to put all of the expectations in one document for Repair and Maintenance

one document for Repair and Maintenance organizations

organizations –

– Military is very interested in having defined Quality Military is very interested in having defined Quality System requirements for MRO

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9120

Distributor Quality System

•

• EN 9120 developed and implemented in

EN 9120 developed and implemented in

Europe for

“

pass through

”

stockists

/

distributors that handle parts and supplies that

are used in aerospace products

–

Checklist 9121 is also available

–

Based on 9100, but only applies

necessary system requirements

.

–

9120 is available

–

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SECTOR / IAQG PROJECTS

•

• Projects are Designed to reduce

Projects are Designed to reduce

requirements variation

•

• Projects are designed to provide

Projects are designed to provide

support and compliance enhancement

to areas that Aerospace has identified

for Risk Reduction (resource limitation)

•

• Projects are designed to increase

Projects are designed to increase

process capabilities

•

• Projects are designed to improve

Projects are designed to improve

products or processes

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Aerospace Quality Standards

(cont.)(cont.)

International Standards

•

• First Article Inspection (9102)First Article Inspection (9102) •

• Management of Key Management of Key Characteristics (9103)

Characteristics (9103)

•

• Record Retention (9130)Record Retention (9130) •

• Nonconformance Nonconformance

Documentation (9131)

•

• 2D Bar Coding (9132)2D Bar Coding (9132) •

• Part Qualification Process Part Qualification Process (9133)

(9133)

Other Projects

•

• ““Less thanLess than”” 9100 (AS9003)9100 (AS9003) •

• Operator Self Verification Operator Self Verification (ARP)

(ARP) •

• Deliverable Software QualityDeliverable Software Quality •

• Non-Non-Deliverable SoftwareDeliverable Software •

• Direct Shipments (ARP 9004)Direct Shipments (ARP 9004) •

• Sampling PlansSampling Plans

•

• 3D Digital Data Storage (ARP)3D Digital Data Storage (ARP) •

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Industry Leaders are Listening

!

! Agreed to improve the overall approach to qualityAgreed to improve the overall approach to quality

!

! Major Aerospace Companies have agreed upon Quality Major Aerospace Companies have agreed upon Quality Management System approval approaches

Management System approval approaches

!

! A key objective is to reduce the number of auditsA key objective is to reduce the number of audits

!

! There are significant benefits to the Aerospace IndustryThere are significant benefits to the Aerospace Industry

!

! Working to develop our International processes to Working to develop our International processes to incorporate the new approach

incorporate the new approach

!

! International approach is based on a single agreed International approach is based on a single agreed standard,

standard, harmonizationharmonization of system application and shared of system application and shared information

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Industry Acceptance / Usage

•

• The IAQG implementation metrics show that;The IAQG implementation metrics show that;

•

• 75+% of members have implemented 9100 internally and 75+% of members have implemented 9100 internally and to their suppliers

to their suppliers •

• 25+% of members have implemented 9102, FAI, internally 25+% of members have implemented 9102, FAI, internally and to their suppliers.

and to their suppliers. •

• 10% of companies have implemented the recently 10% of companies have implemented the recently

published 9103, Component Proving, internally and to their

suppliers.

–

– Implementation is gaining momentum and this will Implementation is gaining momentum and this will increase, particularly when the new Boeing Quality

increase, particularly when the new Boeing Quality

System is reissued.

–

– The sector implementation approaches are also making The sector implementation approaches are also making good progress but the benefits from global mutual

good progress but the benefits from global mutual recognition of Quality System audits is still not quite recognition of Quality System audits is still not quite there yet

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