AEROSPACEAEROSPACEQUALITY MANAGEMENT SYSTEMQUALITY MANAGEMENT SYSTEM 9100 9100

Dale K. GordonDale K. Gordon

Past ChairmanPast ChairmanAmericas Aerospace Quality GroupAmericas Aerospace Quality Group

SAE Aerospace Committee G-14SAE Aerospace Committee G-14September 25th 2002September 25th 2002

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Aerospace Quality StandardsAerospace Quality StandardsNumbering SystemNumbering System

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

sectors and are recognized globallysectors and are recognized globally

Americas Standards - 90xxAmericas Standards - 90xx– Are published for use by AAQG, may become an 91XX Are published for use by AAQG, may become an 91XX

standard at a later datestandard 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”or “SJAC” is the Japan / Asian EquivalentJIS Q”or “SJAC” is the Japan / Asian Equivalent

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Aerospace Quality SystemAerospace Quality System Standards Standards

INTERNATIONAL STANDARDSINTERNATIONAL STANDARDS

– 91009100 - Quality System for Aerospace - Quality System for Aerospace ManufacturersManufacturers

– 91019101 - Checksheet for 9100 - Checksheet for 9100

– 91109110 - Quality System for Aerospace Repair - Quality System for Aerospace Repair Stations Stations

– 91119111 - Checksheet for 9110 - Checksheet for 9110

– 91209120 - Quality System for “Pass-Through” - Quality System for “Pass-Through” DistributorsDistributors

– 91219121 - Checksheet for 9120 - Checksheet for 9120

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

International StandardsInternational 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)Documentation (9131) 2D Bar Coding (9132)2D Bar Coding (9132) Part Qualification Process Part Qualification Process

9133)9133)

Other ProjectsOther Projects

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) Sampling PlansSampling Plans Sub-tier Supplier ControlSub-tier Supplier Control Direct Shipments (ARP 9004)Direct Shipments (ARP 9004) Electronic SignaturesElectronic Signatures Digital Data StorageDigital Data Storage

HISTORY OF 9100HISTORY OF 9100

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Background - Early to mid-Background - Early to mid-1990s1990s

DoD canceled quality system specificationsDoD canceled quality system specifications

FAA lacks a definitive description of a quality FAA lacks a definitive description of a quality systemsystem

Primes began to flow ISO 9000 series plus unique Primes began to flow ISO 9000 series plus unique requirements to suppliersrequirements to suppliers

Suppliers asked industry to standardizeSuppliers asked industry to standardize

– Needed to operate a single quality systemNeeded to operate a single quality system

– Already adopting ISO 9000 seriesAlready adopting ISO 9000 series

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U.S. Industry Response - 1995U.S. Industry Response - 1995

Supplier Management and Quality Assurance professionals from:Supplier Management and Quality Assurance professionals from:

AlliedSignalAlliedSignal Pratt & WhitneyPratt & WhitneyBoeing Boeing Rockwell CollinsRockwell CollinsGE Engines GE Engines Rolls-Royce AllisonRolls-Royce AllisonLockheed Martin Lockheed Martin Sundstrand Sundstrand McDonnell DouglasMcDonnell Douglas Northrop GrummanNorthrop Grumman

SponsorsSponsors

• Aviation/Space & Defense Division ofAviation/Space & Defense Division ofAmerican Society for QualityAmerican Society for Quality

• SAE Aerospace CouncilSAE Aerospace Council

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AAQG Members AgreeAAQG Members Agree

““Where aerospace quality is Where aerospace quality is concerned...there is no concerned...there is no competitive advantagecompetitive advantage””

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FAA

D1-9000ISO-9001

MIL

-IMIL-QDoD

CompanySpecific Req’mtsNASA

Inputs

AS9000:1997

Writing Team FormedWriting Team Formed

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Tier 4 - Make to Print / Machine Shops/ Processors

Tier 2Integrators /

Source Control/Software Dev./

Major Assemblies

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

Tier 1Vehicle / Airframe /Propulsion Manufacture

Tier 3 - Integrators /Source Control / Specialty

Electronics / Wiring / Compnts

Special P

rocesses

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

Company Specific or NADCAP

AEROSPACE SUPPLYAEROSPACE SUPPLY CHAIN CHAIN

Suppliers are NOT

Homogenous

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Global Quality Standard Global Quality Standard ActivityActivity

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ISO TC20 - WG11ISO TC20 - WG11

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

– Established Working Group 11 (April 1997)Established Working Group 11 (April 1997)

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

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

• Members:Members:

BrazilBrazil ChinaChina FranceFranceGermanyGermany JapanJapan MexicoMexicoUnited KingdomUnited Kingdom United StatesUnited States

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ISO TC 20WG11

AS9100 EN 9100

AS9000 prEN 9000-1

AmericasStandard

EuropeanStandardISO 9001

1994

World Aerospace Quality Standard ; AS/EN/JIS Q 9100

International Quality SystemInternational Quality SystemStandard Creation 1998Standard Creation 1998

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Why 9100?Why 9100?

To standardize Aerospace quality To standardize Aerospace quality expectations on a global levelexpectations on a global level

To achieve improvements in quality and To achieve improvements in quality and reduce costs throughout the value streamreduce costs throughout the value stream

ISO 9000 model for quality does not ISO 9000 model for quality does not capture regulatory requirements or capture regulatory requirements or importance of safety, reliability or importance of safety, reliability or maintainabilitymaintainability

Captures aerospace supplements agreed Captures aerospace supplements agreed to at an international levelto at an international level

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Tier 4 - Make to Print / Machine Shops/ Processors

Tier 2Integrators /

Source Control/Software Dev./

Major Assemblies

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

Tier 1Vehicle / Airframe /Propulsion Manufacture

Tier 3 - Integrators /Source Control / Specialty

Electronics / Wiring / Compnts

Special P

rocesses

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

9100

9120

9003

Variation Reduction FAI Process Proving

Company Specific or NADCAP

9110 for Repair Stations

AEROSPACE SUPPLYAEROSPACE SUPPLY CHAIN CHAIN

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Year 2000 ISO 9000 RevisionsYear 2000 ISO 9000 Revisions

A moving target . . .

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

IAQG has the responsibilityIAQG has the responsibility

Aligned aerospace requirements with the new ISO Aligned aerospace requirements with the new ISO 9001:20009001:2000

Incorporated lessons learned - clarified requirementsIncorporated lessons learned - clarified requirements Coordination and resolution was by geographic Coordination and resolution was by geographic

sectorssectors

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

Goal to publish revision to 9100 - est. June 2001Goal to publish revision to 9100 - est. June 2001

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

JIS Q 9100:2001 published by JSA in November 2001JIS Q 9100:2001 published by JSA in November 2001

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ISO 9001:2000 - ISO 9001:2000 - Model of a process Model of a process

based quality management systembased quality management system

CUSTOMERCUSTOMERCUSTOMERCUSTOMER

Continual Improvement of the Quality Management System

ManagementResponsibility

ManagementResponsibility

ManagementResponsibility

ProductRealization

CUSTOMERCUSTOMER

ProductRequirements

Satisfaction

input output

Value added activities

Information Flow

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ISO 9001:2000 QUALITYISO 9001:2000 QUALITYSTANDARD REVISION IMPACTSTANDARD REVISION IMPACT

Aerospace unique requirementsAerospace unique requirementsare not changed in new version ofare not changed in new version of91009100– ISO 9000 revision now has requirementsISO 9000 revision now has requirements

desired by industry, eliminating somedesired by industry, eliminating somerequirements from 9100:1999 versionrequirements from 9100:1999 version

– Some requirements from ISO 9001:1994 are Some requirements from ISO 9001:1994 are desired by industry and were added back to desired by industry and were added back to 9100:2001 version9100:2001 version

– 9100:2000 contains 80 aerospace unique 9100:2000 contains 80 aerospace unique requirements and 18 amplificationsrequirements and 18 amplifications

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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 9100 : 2001

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

9100:2003 ?

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FAA Endorsement of FAA Endorsement of AS9100:1999AS9100:1999

““The Aircraft Certification Service believes that the effective The Aircraft Certification Service believes that the effective implementation of AS9100 will enhance an organization’s overall implementation of AS9100 will enhance an organization’s overall performance, as long as the statement...performance, as long as the statement...Other Quality System Other Quality System requirements imposed by the applicable Regulatory Authorities shall requirements imposed by the applicable Regulatory Authorities shall be included or referenced in the Quality System documentation be included or referenced in the Quality System documentation is is strictly adhered to. Though the FAA does not require the use of the strictly adhered to. Though the FAA does not require the use of the additional elements found in AS9100, it recognizes their benefits to additional elements found in AS9100, it recognizes their benefits to the aviation in increasing an organizations’ efficiency and reducing the aviation in increasing an organizations’ efficiency and reducing product and system variance.”product and system variance.”

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Current USA DoD PositionCurrent USA DoD Position

Proposed Department of Defense (DoD) Adoption of the Proposed Department of Defense (DoD) Adoption of the AS9100: 2001 Quality Management Systems - Aerospace -AS9100: 2001 Quality Management Systems - Aerospace -Requirements (Nov. 2001)Requirements (Nov. 2001)– prepared ... DoD adoption notice for the AS 9100:2001 to prepared ... DoD 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 DoD personnel.document availability to DoD personnel.

International Aerospace Quality Standard AS 9100, 2001 International Aerospace Quality Standard AS 9100, 2001 edition, edition, Quality Management Systems--Aerospace Quality Management Systems--Aerospace Requirements,Requirements, was adopted on March 1, 2002 for use by was adopted on March 1, 2002 for use by the Department of Defense (DoD). The standard the Department of Defense (DoD). The standard specifies additional requirements identified by the specifies additional requirements identified by the aerospace industry specifically for an aerospace quality aerospace industry specifically for an aerospace quality management system based on ISO 9001:2000 management system based on ISO 9001:2000 Quality Quality Management Systems RequirementsManagement Systems Requirements..

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Current NASA PositionCurrent NASA Positionon 9100on 9100

NASA issued Adoption notice on April NASA issued Adoption notice on April 8th 2002, signed by Dr. Michael 8th 2002, signed by Dr. Michael Greenfield, Associate Administrator for Greenfield, Associate Administrator for Mission and Safety Assurance.Mission and Safety Assurance.

This notice makes AS9100A available This notice makes AS9100A available for use by NASA for procurements for for use by NASA for procurements for all programs.all programs.

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SPACE CONSIDERATIONSSPACE CONSIDERATIONS

ISO TC20 / SC14 and IAQG haveISO TC20 / SC14 and IAQG haveon-going project to supplementon-going project to supplement9100 w/ special considerations for9100 w/ special considerations forSpace needsSpace needs– Includes Risk Management & Safety and Includes Risk Management & Safety and

Mission Assurance emphasisMission Assurance emphasis– Use as supplement to 9100Use as supplement to 9100– Consideration for full inclusion at next revision Consideration for full inclusion at next revision

of 9100of 9100

Other Space considerations with IAQG Other Space considerations with IAQG process / documents to be considered as process / documents to be considered as appropriateappropriate

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9100 9100 Checklist - 9101Checklist - 9101

IAQG developed 9101 Common Checklist IAQG developed 9101 Common Checklist to be used by industry to cover all ISO to be used by industry to cover all ISO 9001 & 9100 elements - allows industry to 9001 & 9100 elements - allows industry to share audit information share audit information

Must be used by Certification Bodies Must be used by Certification Bodies when performing 9100 auditswhen performing 9100 audits

Scoring feature is currentlyScoring feature is currentlyused by many organizationsused by many organizations

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9110 9110 Repair Station QualityRepair Station Quality System System

EN 9110 developed and implemented in EN 9110 developed and implemented in Europe for facilities that perform Europe for facilities that perform maintenance and repairs of aircraft and maintenance and repairs of aircraft and aircraft productsaircraft products– Based on 9100 requirements and FAA / JAA - Based on 9100 requirements and FAA / JAA -

JAR 145 requirementsJAR 145 requirements

• Corresponding 9111 checklist has also been developed and published

• Harmonized AS9110 is complete - will be published soon (2002)

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9120 9120 Distributor Quality Distributor Quality SystemSystem

EN 9120 developed and implemented in EN 9120 developed and implemented in Europe for “pass through” stockists / Europe for “pass through” stockists / distributors that handle parts and supplies distributors that handle parts and supplies that are used in aerospace productsthat are used in aerospace products

– Checklist 9121 is also availableChecklist 9121 is also available– Based on 9100, but only appliesBased on 9100, but only applies

necessary system requirementsnecessary system requirements..

– AS9120 International harmonized AS9120 International harmonized standard will be published in 2002standard will be published in 2002

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 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 of system application and shared informationshared information

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Industry Acceptance / UsageIndustry Acceptance / Usage

The IAQG implementation metrics show that;The IAQG implementation metrics show that; 50+% of members have implemented 9100 internally and to 50+% of members have implemented 9100 internally and to

their supplierstheir suppliers 20+% of members have implemented 9102, FAI, internally 20+% of members have implemented 9102, FAI, internally

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

9103, Component Proving, internally and to their suppliers.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.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 - there yet - we need the global database.we need the global database.

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International Aerospace Sector International Aerospace Sector Certification SchemeCertification Scheme

Each geographic region or area needs to establishEach geographic region or area needs to establisha system, based on a set of agreed criteria, a system, based on a set of agreed criteria,

which defines how 9100 will be implementedwhich defines how 9100 will be implemented

We will then have agreed and compatible systemsWe will then have agreed and compatible systemsacceptable to all, which allows us to share audit results acceptable to all, which allows us to share audit results

and approvals resulting in multiple assessment reductionand approvals resulting in multiple assessment reductionand process improvementand process improvement

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What is the Goal of the System?

The goal of the system is for a supplier to receive one9100 quality systems approval that will be acceptableto all aerospace OEMs throughout the world.

The key element in this is confidence. The aerospace OEMs must have confidence in the approvals being given in other Sectors.

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International Requirements for International Requirements for CertificationCertification

International AerospaceInternational AerospaceSupplier Quality SystemSupplier Quality SystemEvaluation/CertificationEvaluation/Certification

Active Industryparticipation

ApprovedAerospaceAuditors

Oversight/control by IAQG

and Sectors

Inter-NationalInter-NationalAviation AuthorityAviation Authority

endorsementendorsement

One audit One audit accepted byaccepted byall Primesall Primes

ApprovedCert. Bodies&

Registrars

Single global standards

9100

Inter-National Accreditation

control

Harmonised systemsof application

Data easily Data easily available to allavailable to all

participantsparticipants

GlobalGlobalacceptance byacceptance bysupplier basesupplier base

Basic structure of the systemBasic structure of the system International Aerospace Audit Approval International Aerospace Audit Approval

ProcessProcess

AmericasAmericas

Americas SchemeAmericas Scheme

Accreditation BodyAccreditation Body RegistrarsRegistrars AuditorsAuditors AssessmentAssessment

SuppliersSuppliersdatadata

Data BaseData Base

IAQG Scheme issued by SAE / AECMA / SJACIAQG Scheme issued by SAE / AECMA / SJAC

EuropeEurope

Aerospace Industry ParticipantsAerospace Industry Participants

Access UsageAccess Usage

AsiaAsia

Asia SchemeAsia Scheme Europe SchemeEurope Scheme

(equivalent)(equivalent) (equivalent)(equivalent)

requirementsrequirements IAQG “oversight”IAQG “oversight”

Accreditation BodyAccreditation Body RegistrarsRegistrars AuditorsAuditors AssessmentAssessment

SuppliersSuppliersdatadata

Data BaseData Base

Accreditation BodiesAccreditation Bodies RegistrarsRegistrars AuditorsAuditors AssessmentAssessment

SuppliersSuppliersdatadata

Data BaseData Base

oversightoversight oversightoversight oversightoversight

WHATWHAT

HOWHOW

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Aerospace Supplier Quality System Aerospace Supplier Quality System Certification by the IAQG SectorsCertification by the IAQG Sectors

Based on Deployment of Sector ProcessesBased on Deployment of Sector Processes– AIR5359 / 5493 (Americas)AIR5359 / 5493 (Americas)– AECMA - QC 24281 (Europe)AECMA - QC 24281 (Europe)– SBAC TS157 (UK)SBAC TS157 (UK)– SJAC 9010 / 9011 (Japan)SJAC 9010 / 9011 (Japan)

• IAQG Document 104 Released Jun ‘01• Industry Database Under Construction

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IAQG Procedure 104IAQG Procedure 104Important ConsiderationsImportant Considerations

Includes requirements for AB’s and CRB’sIncludes requirements for AB’s and CRB’s Includes requirements for auditorsIncludes requirements for auditors

– Training requirements are statedTraining requirements are stated Includes requirements for reporting results of Includes requirements for reporting results of

auditsaudits Includes minimum audit times and guidelinesIncludes minimum audit times and guidelines Industry involvementIndustry involvement

– Must require suppliers to notify OEM’s of status of Must require suppliers to notify OEM’s of status of Registration and any changes theretoRegistration and any changes thereto

– Must report problems with RegistrarsMust report problems with Registrars

– Track suppliers vs. Registrars vs performanceTrack suppliers vs. Registrars vs performance

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9100 9100 Registration AttributesRegistration Attributes

Salient Points about RegistrationSalient Points about Registration– OEM’s are not absolving themselves of any OEM’s are not absolving themselves of any

responsibilities with respect to the supply chain / responsibilities with respect to the supply chain / productsproducts

– Registration increases the level of surveillance by Registration increases the level of surveillance by covering suppliers that the OEM’s do not cover directly.covering suppliers that the OEM’s do not cover directly.

– Provides for consistent application of requirements Provides for consistent application of requirements throughout the supply chain (9100).throughout the supply chain (9100).

– Provides for active industry participation and control.Provides for active industry participation and control.– Provides for data sharing amongst primes and Provides for data sharing amongst primes and

benchmarks the industry in terms of Quality System benchmarks the industry in terms of Quality System compliance.compliance.

– Supplements OEM’s own surveillance process and Supplements OEM’s own surveillance process and allows for more focused process and products audits.allows for more focused process and products audits.

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SummarySummary

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 3rd party approvalsSector processes for 2nd or 3rd party approvals

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

Implementation planned progressively during 2002Implementation planned progressively during 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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QUESTIONSQUESTIONS