AEROSPACE QUALITY AEROSPACE QUALITY MANAGEMENT - INDUSTRY MANAGEMENT - INDUSTRY APPROACHAPPROACH

Mark P. AllenMark P. Allen

ChairmanChairmanAmericas Aerospace Quality GroupAmericas Aerospace Quality Group

SAE Aerospace Committee G-14SAE Aerospace Committee G-14February 14th 2002February 14th 2002

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AAQG LegitimacyAAQG Legitimacy

• Committee of the Society of Automotive Engineers - Committee of the Society of Automotive Engineers - designated Committee G14. designated Committee G14.

• Operations are under the guidance and rules of SAE Operations are under the guidance and rules of SAE committees. committees.

• A cooperative organization within the aerospace A cooperative organization within the aerospace industry in the Americas (including North, Central and industry in the Americas (including North, Central and South Americas). South Americas).

• Processes are established in a set of agreed, Processes are established in a set of agreed, documented, operational procedures. documented, operational procedures.

• Not a legal entity. It is the responsibility of individual Not a legal entity. It is the responsibility of individual companies to implement such agreed upon common companies to implement such agreed upon common procedures.procedures.

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AAQG PurposeAAQG Purpose

Establish and maintain a dynamic cooperation based on trust between Americas Establish and maintain a dynamic cooperation based on trust between Americas aerospace companies on initiatives to make significant improvements in quality aerospace companies on initiatives to make significant improvements in quality performance and reductions in cost throughout the value stream.performance and reductions in cost throughout the value stream.

Initial focus is to continuously improve the processes used by the supply chain Initial focus is to continuously improve the processes used by the supply chain to deliver consistently high quality products, thereby reducing non - value to deliver consistently high quality products, thereby reducing non - value added activities and costs. added activities and costs.

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AAQG and IAQG ObjectivesAAQG and IAQG Objectives

Establish commonality of quality standards and Establish commonality of quality standards and requirementsrequirements– Common aerospace basic quality systemsCommon aerospace basic quality systems– Best practices in aerospace industryBest practices in aerospace industry– Performance metricsPerformance metrics

Establish process of continuous improvement at suppliersEstablish process of continuous improvement at suppliers– Industry expectationsIndustry expectations– Lean manufacturingLean manufacturing– Supplier performance metricsSupplier performance metrics

Establish methods to share resultsEstablish methods to share results– AuditsAudits– InspectionsInspections– Supplier performanceSupplier performance

Establish implementation plans that bring the initiative to lifeEstablish implementation plans that bring the initiative to life– Obtain regulatory concurrenceObtain regulatory concurrence

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AAQG 2002 GoalsAAQG 2002 Goals

Document policies and proceduresDocument policies and procedures

Formalize a charterFormalize a charter

Initiate migration from system compliance to Initiate migration from system compliance to product conformanceproduct conformance

More closely align with industry associations & More closely align with industry associations & other groups to eliminate redundant activitiesother groups to eliminate redundant activities

DoD, Space, AIA…..DoD, Space, AIA…..

Continue project initiations and completionsContinue project initiations and completions

Continuing education for the membershipContinuing education for the membership

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AAQG - MembershipAAQG - Membership Members

Goodrich Boeing Company* Bombardier - Canada* Embraer Aircraft - Brazil* ENAER - Chile GE Aircraft Engines* Gulfstream Aerospace Honeywell* HELIBRAS - Brazil Lockheed Martin*

LMAASA - Argentina Northrop Grumman* Parker Aerospace

Rockwell-Collins Rolls-Royce Corp. Raytheon Aircraft Textron*

Bell Helicopter Cessna Aircraft

United Technologies* Pratt & Whitney Sikorsky Aircraft Hamilton Sundstrand

Vought Aircraft

Non-Voting Members Suppliers RAB IAAR

* Denotes - IAQG Council Member

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AS 9100 Industry Acceptance AS 9100 Industry Acceptance / Usage/ Usage

The IAQG implementation metrics show that;The IAQG implementation metrics show that; 46% of members have implemented 9100 internally and 46% of members have implemented 9100 internally and

to their suppliersto their suppliers 18% of members have implemented 9102, FAI, 18% of members have implemented 9102, FAI,

internally and to their suppliers.internally and to their suppliers. 8% of companies have implemented the recently 8% of companies have implemented the recently

published 9103, Component Proving, internally and to published 9103, Component Proving, internally and to their suppliers. 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.System is reissued.

– The sector implementation approaches are also The sector implementation approaches are also making good progress but the benefits from global making good progress but the benefits from global mutual recognition of Quality System audits is still mutual recognition of Quality System audits is still not quite there yet - not quite there yet - we need the global database.we need the global database.

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9100 Standard Alignment 9100 Standard Alignment with ISO 9001:2000with ISO 9001:2000

IAQG had the responsibilityIAQG had the responsibility

Aligned aerospace requirements with the new ISO 9001:2000Aligned aerospace requirements with the new ISO 9001:2000

Incorporated lessons learned - clarified requirementsIncorporated lessons learned - clarified requirements

Coordination and resolution was by geographic sectorsCoordination and resolution was by geographic sectors

Americas (AAQG)Americas (AAQG) Europe (EAQG)Europe (EAQG) Asia (SJAC)Asia (SJAC)

Goal to publish revision to AS9100 and prEN9100 and any other Goal to publish revision to AS9100 and prEN9100 and any other

translated versions - est. June 2001translated versions - est. June 2001

AS9100A published by SAE in August 2001AS9100A published by SAE in August 2001

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9100:2001 Highlights9100:2001 Highlights

Tokyo, March 2000Tokyo, March 2000

– 1st Draft - Provided to IAQG Sectors for review1st Draft - Provided to IAQG Sectors for review

Seattle, June 2000 Seattle, June 2000

– Consolidation of Sector commentsConsolidation of Sector comments

September, 2000 September, 2000 - Draft updated to 9001 FDIS- Draft updated to 9001 FDIS

Toulouse, November 2000 Toulouse, November 2000

– Continued review and consideration of changes for clarification & Continued review and consideration of changes for clarification & “lessons learned” “lessons learned”

January, 2001 January, 2001 - Draft updated to final ISO 9001:2000- Draft updated to final ISO 9001:2000

New Orleans, March 2001New Orleans, March 2001

– Final Review and approvalFinal Review and approval

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9100:2001 Highlights 9100:2001 Highlights (cont.)(cont.)

Intent of aerospace-unique requirements are not changed Intent of aerospace-unique requirements are not changed in new version of 9100in new version of 9100

– ISO 9001:2000 revision now has requirementsISO 9001:2000 revision now has requirementsdesired by industry, eliminating somedesired by industry, eliminating somerequirements from 9100:1999 versionrequirements from 9100:1999 version

– Some requirements from ISO 9001:1994 are desired by Some requirements from ISO 9001:1994 are desired by industry and were added back to 9100:2001 versionindustry and were added back to 9100:2001 version

– 9100:2001 contains 80 aerospace unique requirements 9100:2001 contains 80 aerospace unique requirements and 18 amplifications/notesand 18 amplifications/notes

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ISO 9001:2000 / 9100:2001ISO 9001:2000 / 9100:2001TimelineTimeline

DEC. 2003

ISO 9001:1994

2000 2001 2002 2003

ISO 9001:2000

9100 : 1999 9100A : 2001

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

9100B ?

Aerospace-Sector Standard Aerospace-Sector Standard Development TimelineDevelopment Timeline

August 2001

1995 1996 1997 1998 1999 2000 2001

T/C 20WG 11

IAQG

Munich

WG 11 Review Review Formed AS9000 prEN9000-1

JointUS/Euro

EN9000-1

AS9000

Initial ARD9000 AS9000Meeting Issued Released

Start prEN9000-1

Philadelphia

Paris

prEN9100

AS9100

Madrid

Tok

yoS

eattl

eT

oulo

use

New

Orle

ans

AS9100A

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Other Party SurveillanceOther Party Surveillance(Americas Companies)(Americas Companies)

– AAQG is implementing SAE AIR 5359A documentAAQG is implementing SAE AIR 5359A document

– AIR 5359A is approved & publishedAIR 5359A is approved & published

– AAQG is working directly with Accreditation AAQG is working directly with Accreditation

Bodies to approve CB’s and AuditorsBodies to approve CB’s and Auditors

– 22 CB’s & 110+ auditors submitted by RAB have 22 CB’s & 110+ auditors submitted by RAB have

been Accredited to AS9000been Accredited to AS9000

– 22 CB’s (and 126 auditors) are Accredited to 22 CB’s (and 126 auditors) are Accredited to

AS9100 at this time. More are expectedAS9100 at this time. More are expected

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THE AMERICAS Other Party System

Registrar Accreditation Bureau

StandardsCouncil ofCanada

INMETRO

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Oversight SummaryOversight Summary

Industry Co-operation on Quality System RequirementsIndustry Co-operation on Quality System Requirements

A single global 9100 Aerospace standard A single global 9100 Aerospace standard

An agreed International process for procedure creationAn agreed International process for procedure creation

Sector processes for 2nd or Other party approvalsSector processes for 2nd or Other party approvals

Individual sector plans launched / global plans in workIndividual sector plans launched / global plans in work

Implementation planned progressively during 2001-2002Implementation planned progressively during 2001-2002

Establish a mechanism for data exchangeEstablish a mechanism for data exchange

International auditor training and qualificationsInternational auditor training and qualifications

Communication to Authorities and StakeholdersCommunication to Authorities and Stakeholders

Industry will Monitor results and maintain momentumIndustry will Monitor results and maintain momentum

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Aerospace Quality System Aerospace Quality System StandardsStandards

INTERNATIONAL STANDARDSINTERNATIONAL STANDARDS

– 9100 - Quality System for Aerospace 9100 - Quality System for Aerospace ManufacturersManufacturers

– 9110 - Quality System for Aerospace Maintenance 9110 - Quality System for Aerospace Maintenance Organizations - Organizations - In workIn work

– 9120 - Quality System for Aerospace Distributors - 9120 - Quality System for Aerospace Distributors - In workIn work

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Aerospace Quality Standards Aerospace Quality Standards (cont.)(cont.)

InternationalInternational

First Article InspectionFirst Article Inspection Management of Key Management of Key

CharacteristicsCharacteristics Record RetentionRecord Retention Nonconformance Nonconformance

DocumentationDocumentation 2D Bar Coding (Draft)2D Bar Coding (Draft) Part Qualification ProcessPart Qualification Process

AmericasAmericas

AS9003 - “Less than” 9100AS9003 - “Less than” 9100 Production Process Planning Production Process Planning

Verification (software)Verification (software) Software Quality (Embedded / Software Quality (Embedded /

Product Acceptance)Product Acceptance) Internal Auditing RequirementsInternal Auditing Requirements Sub-tier Supplier ControlSub-tier Supplier Control Direct Shipments & Electronic Direct Shipments & Electronic

SignaturesSignatures

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Industry Leaders are ListeningIndustry 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 approachesManagement 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 There are significant benefits to the Aerospace IndustryIndustry

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 of system application and shared informationshared information

COPIES OF STANDARDS, REPORTS COPIES OF STANDARDS, REPORTS AND CHECKLISTS ARE AVAILABLE AND CHECKLISTS ARE AVAILABLE FROM SAEFROM SAE

WWW.SAE.ORGWWW.SAE.ORGSociety of Automotive EngineersSociety of Automotive Engineers

400 Commonwealth Drive400 Commonwealth Drive

Warrendale, PA 15096-0001Warrendale, PA 15096-0001

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Aerospace Quality Coordination Aerospace Quality Coordination EffortEffort

Creation of Separate “SPACE, CIVIL & DEFENSE COMMITTEES” Creation of Separate “SPACE, CIVIL & DEFENSE COMMITTEES” under AIA (incl. all associations) under AIA (incl. all associations) – Would meet to address unique needs of each industry Would meet to address unique needs of each industry

segment within the framework of a coordinated Industry segment within the framework of a coordinated Industry process. Would include participation of all affected Industry process. Would include participation of all affected Industry organizations including FAA, DoD and NASA.organizations including FAA, DoD and NASA.

AAQG process would remain unchangedAAQG process would remain unchanged– AIA Committees would join with the AAQG to integrate AIA Committees would join with the AAQG to integrate

strategy and develop the products and tools needed for strategy and develop the products and tools needed for implementationimplementation

– AAQG responsible for common standards, tools and AAQG responsible for common standards, tools and methods with supplementation for specific sector needsmethods with supplementation for specific sector needs

Involve NADCAP Activities with AAQGInvolve NADCAP Activities with AAQG– Special Process issues would be assigned to NADCAP and Special Process issues would be assigned to NADCAP and

Quality Systems would be handled through the AAQGQuality Systems would be handled through the AAQG

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AIA-SMCAQWG

NADCAP

Civil Aviation Quality

Committee

DefenseQuality

Committee

SPACEQuality

CommitteeNASA

AIAA

FAA

NDIA /EIA

DoD

CIV

IL A

VIA

TIO

NM

ILIT

AR

YS

PA

CE

Suppliers

TACTICAL

Arrangement of Quality Arrangement of Quality CommitteesCommittees

OEM’s /

PAHs

ASA /ARSA

AIA / GAMA

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SINGLE VOICE FOR QUALITY IN SINGLE VOICE FOR QUALITY IN AEROSPACE INDUSTRYAEROSPACE INDUSTRY

Proposal would Eliminate overlap in Committees and Proposal would Eliminate overlap in Committees and OrganizationsOrganizations– Reduction in resources and travel costs for participantsReduction in resources and travel costs for participants– Eliminate redundant activitiesEliminate redundant activities

Increase in Communications between Groups and LeadershipIncrease in Communications between Groups and Leadership– Focus customer and user information in many areasFocus customer and user information in many areas– Increase response and decision time for implementationIncrease response and decision time for implementation– Obtain broader involvement of suppliers, customers and Obtain broader involvement of suppliers, customers and

regulatorsregulators– Better coordination / implementation of government / industry Better coordination / implementation of government / industry

initiativesinitiatives

Provide inputs and coordination for Global Quality Issues for the Provide inputs and coordination for Global Quality Issues for the International Aerospace Quality GroupInternational Aerospace Quality Group

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ORGANIZATIONAL BENEFITS TO ORGANIZATIONAL BENEFITS TO INDUSTRYINDUSTRY Executive Quality GroupExecutive Quality Group

– Clear senior level direction with supporting resourcesClear senior level direction with supporting resources

– Ability to challenge the status quoAbility to challenge the status quo

– Includes representation from Industry AssociationsIncludes representation from Industry Associations Americas Aerospace Quality GroupAmericas Aerospace Quality Group

– Development of industry-wide (global) processes when Development of industry-wide (global) processes when appropriateappropriate

– Linkage with international organizations and initiatives Linkage with international organizations and initiatives through the IAQGthrough the IAQG

– Official alignment with an ANSI recognized Standards Official alignment with an ANSI recognized Standards Development Organization (SAE)Development Organization (SAE)

– Commitment to use products both internally and with Commitment to use products both internally and with supplierssuppliers

– Formal linkage to the supplier communityFormal linkage to the supplier community

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ORGANIZATIONAL BENEFITS TO ORGANIZATIONAL BENEFITS TO INDUSTRYINDUSTRY

AIA managed business-line unique Committees (Civil, AIA managed business-line unique Committees (Civil, Defense and Space)Defense and Space)– Involvement of all stakeholders - customers, suppliers Involvement of all stakeholders - customers, suppliers

and associationsand associations– "Authorized" linkage to political and "Authorized" linkage to political and

government/regulatory organizationsgovernment/regulatory organizations– Communication with a business-line and across parallel Communication with a business-line and across parallel

business-linesbusiness-lines– Linkage to other AIA Councils and Industry Linkage to other AIA Councils and Industry

AssociationsAssociations

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EXECUTIVE QUALITY GROUP

AM

ER

ICA

S A

ER

OS

PA

CE

QU

AL

ITY

GR

OU

PNADCAP CIVIL AVIATION DEFENSESPACE

AAQG would perform Integration AAQG would perform Integration Function (incl International)Function (incl International)

Working

Teams

Working

Teams

Working

Teams

Working

Teams

STRATEGY&

RESOURCESVALIDATION

INDUSTRY QUALITY POSITIONS / ACTIONS

STANDARDS

COMMUNICATIONS

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Proposal for New Aerospace Proposal for New Aerospace Quality Coordination EffortQuality Coordination Effort

Monday Tuesday Wednesday Thursday

Series of Structured Meetings in the Washington D.C. Area Twice a Year

CIVILAVIATION

DEFENSE

SPACE

Working

Teams

Working

Teams

Working

Teams

Working

Teams

AM

ER

ICA

S A

ER

OS

PA

CE

QU

AL

ITY

GR

OU

P

NADCAPEXECUTIVE

BOARDMEETING

EXECUTIVE QUALITYGROUP

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AerospaceAAQG Commercial Space DoD

Council Chairs Mark Allen Andy Brindisi ? ?

Standards (PT-S) Dennis Lemon x x x

Tools & Techniques (PT-T) Julie Sandrers x x x

Implementation (PT-I) D. Buehler x x x

Communications (PT-C) C. Adkisson x x x

Industry Segment Councils

Industry Industry Segment Segment

TeamsTeams

Aerospace Aerospace Project Project TeamsTeams

Leadership team includes:AAQG & Industry Segment ChairsVice-Chair - Colin ClarkeSecretary - Carolyn AdkissonTresurer - Gretchen BrothersSAE - Jay Myers, Gretchen BrothersProject Managers

AAQG Management ApproachAAQG Management Approach

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Next MeetingsNext Meetings

June 3-5, Boston, MAJune 3-5, Boston, MA

Sept. 9-11, Washington, DCSept. 9-11, Washington, DC

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QUESTIONSQUESTIONS

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Back-upBack-up

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The International Aerospace The International Aerospace Quality GroupQuality Group

IAQG

IAQG Council

IAQG General Assembly

Meetings

JAQG

SJAC

AAQG

SAE

EAQG

AECMA

National Trade

Associations

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IAQG MembersIAQG Members

•Europe• Airbus• EADS - Airbus/BDLI• Rolls-Royce and SBAC• EADS (France)• ALENIA and AIAD• SNECMA• EADS - CASA and

ATECMA• BAE Systems• Agusta• Aermacchi• Eurocopter• Dassault• Intertechnique/GIFAS• MTU Aero engine• AECMA• Volvo-Aero

•Americas• The Boeing Company• GE Aircraft Engines• Pratt & Whitney/UTC• Rockwell Collins• Honeywell• Northrop Grumman• Cessna - Textron• Rolls-Royce Corp.• Gulfstream• Embraer• BF Goodrich• Bombardier• Bell Helicopter

Textron• Lockheed Martin• Raytheon• Vought Aircraft

• Hispano-Suiza• Turbomecca• Messier-Bugatti• Thompson-CSF Sextant

•Asia• Ishikawajima Harima Heavy

Industries• Mitsubishi Heavy Industries• Kawasaki Heavy Industries• Fuji Heavy Industries• Shin Mayawa Industries• Aviation Industries of China• Korea Aerospace Industries

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Aerospace Quality StandardsAerospace Quality StandardsNumbering SystemNumbering System

International Standards - 91xxInternational Standards - 91xx– Are planned for harmonization across all 3 Are planned for harmonization across all 3

aerospace sectors and are recognized globallyaerospace sectors and are recognized globally

Americas Standards - 90xxAmericas 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 date91XX standard at a later date

““AS” Standards - AmericasAS” Standards - Americas– Published by Society of Automotive EngineersPublished by Society of Automotive Engineers

““EN” Standards - EuropeEN” Standards - Europe– published in Europe by AECMApublished in Europe by AECMA

““JIS Q” is the Japan / Asia EquivalentJIS Q” is the Japan / Asia Equivalent

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Governance DocumentsGovernance Documents

2

CharterCharter 100100ProcedureProcedure

EstablishmentEstablishment

102102CommitteeCommittee

MembershipMembership

103103Maintenance Maintenance of Standardsof Standards

104104CommitteeCommitteeMeetingsMeetings

SAESAEOperating Operating

GuideGuide

SAESAETech Stds BoardTech Stds Board

GovernanceGovernance

101101Project Project InitiationInitiation