Boeing Supplemental Oversight Supplier Quality / BOR Function BOR Team Communication with CB • Boeing Oversight Representatives hold the Responsibility, Accountability and Authority

BOEING is a trademark of Boeing Management Company.Copyright 2005 Boeing. All rights reserved.

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Boeing Supplemental Oversight

Auditor Day - Italy

Marco Pellegrini Date: 19th September 2014

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Introductions

Marco PellegriniBoeing Commercial Airplanes

Supplier Quality

United Kingdom

With Boeing since 2006, BOR since 2011


Boeing Supplier Quality / BOR Function

Boeing Supplier Quality / BOROrganizational Relationship within Boeing

Global organization, supporting suppliers in all regions Americas, Europe, Asia-Pacific

Responsibilities Quality Management System (QMS) and Special Process approval and maintenance

Recognition of certification Performing assessments

Validating product and process conformance to requirements

Supplier development, including training and performance improvement

Customer Complaints resolution and corrective action

Personnel competencies include QMS (ISO9001/AS9100) and auditing (ISO19011)

Boeing Supplier QualitySupplier Quality Organization Responsibilities

Product conformance Source acceptance (prior to shipment) In-process inspections and special inspections Conformity Inspection (as applicant and/or FAA designee) First Article Inspection (FAI) Verification

Assessments Quality Management System Product Manufacturing Processes Special Processes Digital Product Definition Tooling Software

Boeing Supplier QualitySupplier Quality Field Rep Responsibilities

BOR Team Staffed by Supplier Quality Field Representatives

Additional work statement and responsibilities

Qualified individual who meet the requirements of Other Party Assessors per AS9104-002

Responsibilities Support SQ Field Representative questions/issues/concerns regarding certification recognition

Analyze/monitor CB performance using client (Boeing supplier) performance (CB Report Cards)

Perform supplemental oversight described in 9104-002, 7.13

Maintain Records of supplemental oversight

Attend/support aerospace industry certification scheme groups and meetings IAQG, AAQG, Other Party Management Team (OPMT), etc.

Present supplemental oversight results, conduct training workshops, etc.

Support IAQG initiatives and standards AS9101 Rev D, AS9102 FAI, AS9100, etc.

Boeing Supplier Quality / BOR FunctionBoeing Oversight Representative (BOR) Responsibilities

T.Coulter(BCA)

K.Hara*(BCA)

B.Simons*(BCA)T.Lee

(BCA)

M.Pellegrini(BCA)

T.Marino(BDS)

T.Chisholm(BCA)

R.Borrelli(BDS)

B.Aldrich(BCA)

D.Castaneda(BDS)

J.Johnson(BDS)

L.Price(BDS)

T.Cupples(BCA)

BORTeamLead

BORTeamMember

A.Levhar*(BDS)

G.Barnes*(BCA)

* Limited support as needed

BoeingSupplierQuality/BORFunctionBORRepresentativesandLocation

SQIT

Executive SponsorsBCA George

BuswellBDS Larry Weng

Process LeadsBDS Tony Marino

BCA Tim Lee

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US/Canada Oversight Representatives

Robin Borrelli BDS, East Tom Coulter BCA, West Dan Castaneda BDS, West Linda Price BDS, CaliforniaTerry Cupples BCA, CaliforniaBruce Aldrich BCA, EastJerry Johnson BDS, WestTom Chisholm Winnipeg

International Oversight RepresentativesMarco Pellegrini BCA, EuropeBrian Simons BCA, Asia*Kinsuke Hara BCA, Japan *Gordy Barnes BCA, Europe *Avihay Levhar BDS, Israel *

* Limited support - as needed

BOR Team Structure

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BOR TeamManagement Tools

Internal - SharePoint EITMS Group Mail Box Activity Log

External - Team Managed OASIS Account

Boeing Supplier Quality / BOR Function BOR Team Communication with CB

Boeing Oversight Representatives hold the Responsibility, Accountability and Authority at Boeing to communicate with CB and Accreditation Body (AB) via the OASIS Feedback Loop on Certification Activities.

BOR Team primarily uses OASIS for communication, informal follow-up may be made via E-mail and/or phone calls.

OASISFEEDBACK LINKAGE USED TO

CBEXPECTATIONS

Manual

BOR Rep requests / inputs information in OASIS

Communicate CB report card Notify of supplemental oversight

activity. Coordinate general inquiries

regards certification status

Utilize report card data asneeded on focus areas.

Respond to inquiries within 1 month (per AS9104)

Automated

Boeing Integrated Supplier Information System (ISIS) automatic upload to OASIS

BOR / CB follow-up communication resulting from a ISIS Upload

Communicate when a Major nonconformance is issued against a suppliers QMS.

Communicate when a supplier is put on Probation

Review affected AS9100 elements for Major SERs issued at next on-site

Conduct short notice audit when a supplier is placed on probation

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Boeing Supplier Quality / BOR FunctionBOR Process Summarized

CB OVERSIGHT ACTIVITY Audit Report Review

AS9101 Reports

Onsite Assessment at Supplier Client Validation (Audit Report Review & QPA 119)

CB Office Visit Working together and supplier file review

CB Witness Audit Auditor competency

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Boeing Supplier Quality / BOR FunctionBOR Team Communication with CB

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Data Drives BOR Activities BOR Support request

BOR activity Log

(might result in)

Supplemental Oversight

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CB Report Cards - Risk Based Management

Used to identify high risk CBs based on client performance data (X) and side of client base (Y). Data is pulled directly from ISIS Distributed by the BOR team to the applicable CBs every 6 months Includes Detailed Definition of Metrics (SER, NOE, Client List Data) Measure level of influence (Boeing suppliers on Y axis) 17 Performance Measures (X axis)

Number of Clients Increase Over Time SER's MAJOR / SER's Minor NoE's (#) BEST Quality rating (average) Probation (past 12 months) CB Form D Major/Minor (12 mos) Product NCR's (6 months) RCCA (#) Elevation to AB (#)

CBs are advised to utilize the detail data worksheets provided in the Report Card to identify performance issues of clients listed. This may include but not be limited to.

Identifying AS9100 elements of a organization that may warrant further review Determining Audit time applied depending on the quantity of issues identified

Data Drives BOR Activities CB report cards

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Risk Based Management

CB Report Card Data fed into risk analysis tool.

Used to identify high risk CBs based on client performance data and side of client base.

Data Drives BOR Activities CB report cards

TipsonUsingtheCBReportCardData

Tip 2:Use NoE data for affected clients

when developing the audit plan

Tip 1:Use SER data for affected clients when developing the audit plan.This data includes Minor and

Major QMS Nonconformance's including the affected AS9100

element.


ICOP supplemental oversight 2013 - 2014

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Supplemental CB Oversight Events (58 Completed) 13 CB Office Visit

2 Europe, 1 Japan 7 Witness Audits 36 Adhoc Events Upon Request

Client Validations, Audit Report Reviews, Certificate Authentications

Industry Shared Oversight Activity (Industry commitment met) 2 office visits complete 3 witness audit complete 1 RAB QSA office audit 2 Market Surveillance Events

Results: 27 Form D nonconformance's generated by Boeing

CB Corrective action required Coordinated with Accreditation Body (AB) and will be verified during CB office visits CB concerns elevated to ANAB for resolution

Boeing Executive Engagement

2013 ICOP OversightSupplemental Activity Results

CB PerformanceNonconformance Activity (AS9104-002 Form D)

Breakdown of Form Ds issued by Boeing during Boeing Supplier and CB Surveillance activities.

Form Ds issued by Boeing are taken into consideration of CBs Report Card.

2014 ICOP Oversight PlanCB Risk Analysis

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Planned Oversight for Red CB's Office Visits = 16 (Red CB with No 2013 Office Visit or X value > 350)Client Val = 6 (Red CB with 2013 Office Visit and X value < 350)

22 Red CBs15 - Americas6 Europe1 Japan

BORDER CalculationsRisk Analysis

Updated: 15th Sep 2014

BOR update supplemental oversight activity - Europe

UK: 4 CB Office visits conducted in the UK

2 Boeing only 6 NCRs raised (2 Major) 1 with UKAS 6 NCRs raised by UKAS 1 with ANAB 2 NCRs raised by ANAB

1 CB witness audit planned for Sep. 2014 1 Elevation to AB

Europe (other than UK): 2 CB Office visits conducted in Europe (Italy, France) 2 Audit report reviews (Form N) conducted in Europe (Italy, Germany)

(all Boeing only) 6 NCRs raised (3 Major) 1 CB witness audit planned for Nov. 2014 1 Elevation to AB

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BOR update - general feedback (Europe)

Observed areas of general concern:

Management of NCRs Weak corrective actions plans to NCRs raised, accepted by auditors Poor verification conducted (often remotely). Verified execution of corrective

actions, not the effectiveness.

Audit Calculation Minimum audit days utilized, without justification (required by 9104-001)

Certification Structure Eligibility Criteria E.g.: campus affecting audit duration

Control of local (overseas) offices for clients in Asia Inconsistent grading of NCRs classification, appearance of less thorough audit


Boeing Supplier QualityRequirements and Processes

http://www.boeingsuppliers.com/

Boeing Supplier Quality Requirements and ProcessesCustomer Requirements

BCA BDS

D6-82479 Boeing Quality Management System Requirements for Suppliers

D1-4426 Boeing Approved Process Sources

D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing suppliers

AS9102 First Article Inspection

X31764 BCA Quality Purchasing Data Requirements

N/A

Boeing utilizes contract/purchase order notes to flow down requirements BDS contract notes are available on external web-site BCA contract notes are available on internal (Boeing Partners Network)

web-site. The table at right is a example of some of the Key, top level contract

requirements which Boeing flows down to its suppliers. These are accessible on the external web.

Key Points in D6-82479 Supplier is required to obtain certification/registration through an accredited Certification Body.

Depending on the type of product/services provided, different sections of D6-82479 may be applied. Contract/PO Notes are used to defined which sections apply.

Boeing reserves the right to change Boeing approval status of a supplier and/or to terminate the recognition of the Sellers certification, regardless of previous or current recognition.

Supplier is required to notify Boeing when: Supplier changes a CB Certification is suspended or withdrawn by a CB

Boeing identified findings and sellers quality performance data is provided to the CB during certification, registration and surveillance activity.

Seller receipt of Boeing QMS nonconformance that is classified as Major, against Seller's QMS, Seller shall coordinate with the CB in order to provide awareness and description of Corrective Action taken

In the event that Boeing changes Sellers approval status from Approved to Probation or Disapproved; Seller will notify their CB within five business days and make arrangements for a Special Short-notice Audit(Reference ISO 17021 paragraph 9.5.2, AS9104A 8.2.3 / AS9104/1 8.1.3). This audit scope will include investigation of nonconformities that resulted in the change of status to Probation or Disapproval and assessment of impact to certification.

Boeing Supplier Quality Requirements and ProcessesD6-82479 Quality Management System Requirements

APPLICATION USED FOR

ISISIntegrated Supplier Information System

Communication of Quality Management System (QMS) findings on Supplier Evaluation Report (SER).

Communication of Product Nonconformance issues found within the Boeing Factory.

BESTBoeing Enterprise Supplier Tool

Communication of a suppliers performance at the Boeing Enterprise, Group and Site levels.

ASAPAutomated Source Activity Planning System

Recording of Source Acceptance Results (accept and reject)

Recording of Boeing pick-ups (SRD Supplier Rejection Document) at Source

Note: ASAP will migrate over to ISIS system in 2016.

Boeing Supplier Quality Requirements and ProcessesCustomer Satisfaction

Clients can demonstrate Boeing (Customer) Satisfaction via three applications with the Boeing Partners Network system.

Boeing Supplier Quality Requirements and ProcessesCustomer Satisfaction - ISIS

AUDITING TIP:Ask the client to show their ISIS application, check for Past due nonconformance review or C/A activities. Stated Corrective Action plans followed. Select a product nonconformance and determine if

client has addressed the issue.

Boeing Supplier Quality Requirements and ProcessesCustomer Satisfaction - BEST

AUDITING TIP:

Have the Supplier access the BEST application.Note: only specified account holders may have a BEST application typically Quality and/or Program mgmt.

If the supplier has contracts with multiple Boeing sites drill down and review the Group Performance ratings.

Clicking on the Quality and Delivery hyperlinks will provide specific rejection documents, trace this within the suppliers C/A system.

Does the Management Review include the Group Performance (i.e. individual sites) as well as the Composite Rating (Boeing Enterprise)?

Boeing Supplier Quality Requirements and ProcessesCustomer Satisfaction - ASAP

AUDITING TIP:

If Boeing Source Acceptance is a contract requirement: Ask the supplier to

show the ASAP application

Have them run a report of source pick-ups (SRD Source Rejection Document).

Determine if the SRD data is used for corrective action activities.

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Communications

CB Awareness Information Tri-folds OASIS (General Feedback, Major Nonconformance,

Probation)

Customer Satisfaction (ISIS-BEST-ASAP)

Boeing external Websites (Boeing Quality Management Systems requirements)

BPN (Boeing Partner Network)

Customer Overviews (FAA/DCMA/NASA) IAQG Committees (AAQG/EAQG/APAQG)

OASIS_Tri_Fold

Customer satisfaction

External websites

BPN

Major Nonconformance

Probation

General Feedback

Red FlagsExpectations

This information is provided by the Boeing Oversight Representative team for use by interested parties to understand AS9100 Customer Expectations and/or requirements as they relate to suppliers of The Boeing Company.

Copyright 2014 Boeing. All rights reserved. 261939 03/2014

Response to OASIS feedback is provided by the CB within the timeframe requested in the feedback.

Special short-notice audits are conducted by the CB at clients facility when Boeing places the client on probation for poor performance. Special audits evaluate depth and breadth of issue(s) and determine status of existing certification.

Major SER raised against a CBs client by Boeing are included as part of the CBs surveillance or short-notice audit activity to evaluate the applicable processes of the QMS for which the SER was raised. Note: Boeing does not expect CB auditors to accept or verify responses to Boeing nonconformances.

A single major SER nonconformance does warrant additional investigation, and based on available client performance data (past CB NCs, PEARs, customer complaints, etc.) a short notice audit may indeed be warranted. However, our expectation would be to ensure that the associated process is evaluated at the next scheduled audit.

Certification body does not utilize OASIS Major Nonconformance Notifications as part of their audit and certification of their client.

Special short-notice audits are not scheduled within a reasonable amount of time when a CBs client has been put on probation by Boeing and the CB is notified via OASIS.

When submitted by BOR team through OASIS, response to general inquires is late or lacking.

There is no evidence in audit report of feedback follow-up.

OASIS Online Aerospace Supplier Information System

OASIS Feedback

Boeing OASIS Feedback

Boeing Oversight Representitives (BOR) hold responsibility, accountability, and authority at Boeing to communicate with certification bodies (CB) and accreditation bodies (AB) through the OASIS feedback loop on certification activities.

BORs are qualified individuals who meet the requirements of Other Party Assessors per 9104-002, Requirements for Oversight of Aerospace Quality Management Registration/ Certification Programs.

Effective Jan. 1, 2013, a BOR team OASIS administration account (BOR Team) has been established. This ensures that there is one common voice from Boeing.

BOR communication through OASIS is both automated and manual.

Automated Feedback Boeing Integrated Supplier Information System (ISIS) automatically uploads certain data to OASIS. This creates a Feedback Ticket to the clients CB when either of the following conditions are met:

Major Quality Management System (QMS) nonconformance documented against a CBs client by Boeing on a Supplier Evaluation Report (SER).

CBs client is put on probation by Boeing due to poor performance.

Manual Feedback

BOR may issue manual feedback requests in OASIS. Examples of manual feedback include

Notification for an audit report review.

Request to participate as an observer or witness during an audit.

Request for information.

Providing biannual CB Report Card.

Schedule on-site CB office visit.

Process Score

Special short-notice audit is conducted within 8 weeks of being notified that Boeing has placed the CBs client on probation.

SERs raised by Boeing against a CBs client are included in the clients audit folder/file to be used to review the affected QMS element at the next audit activity.

Consideration for a special short-notice audit is made when the CB receives a major SER notification issued against a CBs client. Decision to conduct a special audit is based on the major SER and client performance data generated by the CB.

Audit records contain reference to Boeing major nonconformance issues and have objective evidence of audit of the element of the QMS where the nonconformance was raised.

Responses to general inquiries are provided by the dates requested and/or agreed upon.

Rate your own OASIS feedback performace. Rate on a scale of 1 to 5.

Red FlagsExpectations



Client should be aware of Boeing customer feedback methods.

Client should actively review and utilize feedback data throughout the organization.

When requested, corrective action responses by the client are provided to Boeing on time and with first-time quality (no rejected responses due to incomplete or inadequate information).

BEST data at the applicable enterprise, group, and site levels is part of clients management review.

Auditing Tips

Have the organization demonstrate how it incorporates data from the Integrated Supplier Information System (ISIS), Boeing Enterprise Supplier Tool (BEST), and Automated Source Activity Planning (ASAP) within its Quality Management System. Note: ISIS, BEST, and ASAP are applications within the Boeing Partners Network (BPN) system.

Review ISIS corrective action and Supplier Evaluation Report (SER) responses for

Corrective action implementation activities and whether dates were met.

Rejection of responses provided (inadequate corrective action responses).

Integrated Supplier Information System (ISIS)

Product nonconformances transmitted through ISIS are not being reviewed in a timely manner, or rejection is not validated in the production system

Past due corrective action (C/A) responses

Extension requests for C/A response submittal

Boeing rejected C/A responses

No and/or limited objective evidence documented for stated C/A

Automated Source Activity Planning (ASAP)

Reporting function is not utilized to trend source rejection issues

Boeing Enterprise Supplier Tool (BEST)

No consideration of performance level at the individual site level, only at the composite level

ISIS

BEST

ASAP

ISIS Intergrated Supplier Information System

ASAP Automated Source Activity Planning

BEST Boeing Enterprise Supplier Tool

Communication of Quality Management System (QMS) findings are reported on a Supplier Evaluation Report (SER).

Communication of product nonconformances found within the various Boeing factories are communicated on any one of the following types of Corrective Action (C/A) requests.

Nonconformance Notification No response due to Boeing; however, organization is expected to review the nonconformance and take appropriate action.

Immediate Correction Response due to Boeing providing containment actions and correction of the nonconforming condition.

Immediate Action Response due to Boeing providing the action taken to eliminate the direct cause of the nonconformance.

Root Cause Corrective Action Response due to Boeing providing complete RCCA activities.

Composite-Reflects the performance of all Boeing sites

Group-Reflects the performance of Boeing Defense, Space & Security or Boeing Commercial Airplanes

Site-Reflects the performance at the individual BDS or BCA site

Performance is reported for both Quality and Delivery at five performance levels.

Sample BEST report. Does not reflect actual ratings.

Example:

Ratings can be displayed at various levels.

Gold

Silver

Bronze

Yellow

Red

Boeing source acceptance activities are recorded in this system.

Source acceptance results (product accept and reject) are included in ASAP.

The source rejection document within ASAP defines specific product accept or reject issues.

The reporting function within ASAP allows a supplier to download rejection information and develop corrective action to avoid rejection at future source activities.

Color Score for quality

Score for On Time Delivery (OTD)

Gold 100% 100%

Silver 99.8 - 99.99% 98.00 - 99.99%

Bronze 99.55 - 99.79% 96.00 - 97.99%

Yellow 98.00 - 99.54% 90.00 - 95.99%

Red less than 98.00% Less than 90.00%

NN

IC

IA

RCCA

Red Flags

Client does not notify certification body within five days if they have been placed on probation (D6-82479).

Client does not verify the use of special process facilities when applicable (D1-4426).

Client is not aware of how to identify if a Boeing process is considered to be a special process.

Derivative data sets are not controlled, identified, or traceable to the source file (D6-51991).

Planning/traveler is not traceable to the authority data set (D6-51991).

Implicit design characteristics are not identified within the FAI Report (D6-51991).

Client is not aware of which requirements from website provided are applicable or how to find them.

Auditing Tips

Check to see if there are any Online Aerospace Supplier Information System (OASIS) feedback tickets for major nonconformances issued by Boeing. Review the associated clauses during the audit.

Look at a fabrication or purchase order that includes a Boeing defined special process and verify that the processor is listed in D1-4426.

Find a part that is defined by model; verify that the implicit features of the model are captured in the First Article Inspection (FAI) Report. Verify if client has D6-51991 approval/ documented procedures for using digital product definition models.


Copyright Boeing. All rights reserved. 261939 03/2014

BoeingExternal WebSupplier Requirements

BQMS

DPD

Special Process

External Web

Web Data Includes

Terms and Conditions (as may be flowed down to contracts)

Boeing Commercial Airplanes (BCA) specific Quality Purchasing Requirements

Boeing Defense, Space & Security (BDS) Site/Program Quality Requirements

Boeing Quality Management System (BQMS) requirements for suppliers (as flowed down via contract clauses)

Boeing special process requirements

Boeing requirements for digital product definition

Login to Boeing Partners Network (BPN)

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D6-84279, Boeing Quality Management System (BQMS) Requirements

Flowed via contract note by the procuring Boeing site

Prime document that flows down 9100, 9110, and 9120 provisions

Defines Boeing recognition and requirements for use of accredited certification bodies (CB)

Defines key characteristic and software requirements

D6-51991, Quality Assurance Standards for Digital Product Definition (DPD)

Expectation for the receipt, control, and use of digital data

Checklist guide to determine compliance of D6-51991

D1-4426, Boeing Approved Process Sources (Special Processes)

Listing of all Boeing specifications considered to be a special process

List of all Boeing approved special process sources

Specific Site, Customer, and General Terms and Conditions Requirements

Boeing Commercial Airplanes (BCA) additional requirements (Form X31764)

Boeing Defense, Space & Security (BDS) site requirements

BDS quality clauses (BCA is in Boeing Partners Network (BPN), not on external website)

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Red Flags

Drawing/document/specification revisions from the following BPN applications are not in agreement with revisions implemented by the organization:

Supplier Data Transmittal (SDT)

Engineering Information Delivery (EID)

Product Standards Data System (PSDS)

Supplier Product Data Management (SPDM)

ISIS, BEST, and ASAP data should be used as a part of customer satisfaction and not customer complaints.

Organization does not have a process to capture and route supplier bulletins provided for awareness.

Expectations Auditing Tips

Process implementers should have access to and knowledge of the BPN BEST applications they use.

Drawings, specifications, and requirements obtained or uploaded with BPN applications are implemented within the organization at the current revision.

Customer satisfaction is measured from data available in BPN scores and Notice of Escapements (NOE).

For Boeing designed build-to-print products, has the organization demonstrated their use of the EID system and product standards for configuration control?

For a supplier designed product, has the client demonstrated their use of SDT for latest design acceptance by Boeing?

For customer satisfaction, has the client demonstrated how data from BEST, ISIS, and ASAP applications are used?

How does the organization ensure that the latest documents in SPDM are utilized?



BPN Boeing Partners Network

Design Status

Customer Feedback

Performance

Supplier Portal

My Information

Data will show which individuals within an organization have BPN accounts and which application for which they have access.

BCA Supplier Bulletins

Bulletins provide updates and/or reminders of Boeing requirements.

Key Process: Customer Requirements

My Products (BPN Applications)

Access to applications is granted at the User ID level, and application access will vary between individuals within the organization.

EID Drawing Search

Latest Boeing drawing can be seen here after it has been released to the organization by Boeing.

Product Standards Data System

Latest Boeing process/material specification can be seen here after it has been released to the organization by Boeing.

BPN Application Name Purpose Key Process

Boeing Enterprise Supplier Tool (BEST) Quality and delivery rating and performance. Customer Satisfaction

Automated Source Activity Planning (ASAP) Product acceptance or rejection during source inspection. Customer Satisfaction

Integrated Supplier Information System (ISIS) Client fault product nonconformance and Quality Management System nonconformance.

Customer Satisfaction

Supplier Product Data Management (SPDM) Requirement documents that are not design or process related.

Configuration Management

Supplier Data Transmittal (SDT) Submittal and disposition (accept/reject) of supplier designs.

Configuration Management

Purchase order (PO) notes PO notes for BCA only. BDS PO notes are external. Customer Requirements

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Questions

Questions???

We welcome feedback on our process.

The following Boeing Oversight Group Email account may be utilized to provide feedback, ask questions or raise a complaint/concern:

[email protected]

Thank you for supporting this activity!!!

Documents

Boeing Supplemental Oversight Supplier Quality / BOR Function BOR Team Communication with CB • Boeing Oversight Representatives hold the Responsibility, Accountability and Authority