AEROSPACE QUALITY AEROSPACE QUALITY MANAGEMENT SYSTEM MANAGEMENT SYSTEM STANDARD AS / EN / JIS Q9100STANDARD AS / EN / JIS Q9100

Dale K. Gordon

ChairmanAmericas Aerospace Quality Group

SAE Aerospace Committee G-14

20 February 2001 2

Aerospace Quality StandardsAerospace Quality Standards Numbering System Numbering System

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

aerospace sectors and are recognized globally

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

91XX standard at a later date

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

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

“JIS Q” is the Japan / Asia Equivalent

20 February 2001 3

Aerospace Quality SystemAerospace Quality System Standards Standards

INTERNATIONAL STANDARDS

– 9100 - Quality System for Aerospace Manufacturers

– 9101 - Checksheet for 9100

– 9110 - Quality System for Aerospace Repair Stations - EAQG

– 9111 - Checksheet for 9110 - EAQG only

– 9120 - Quality System for Distributors - EAQG

– 9121 - Checksheet for 9120 - EAQG

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FAA

D1-9000ISO-9001

MIL

-IMIL-QDoD

CompanySpecific Req’mtsNA

SA

AS9000

Inputs

AAQGProcess

Output

European

Specific Stds

AAQG formed in 1995 to Standardize Quality Requirements for the Industry

HISTORY - The need to StandardizeHISTORY - The need to StandardizeAerospace Quality System RequirementsAerospace Quality System Requirements

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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 AS9100?Why AS9100?

To standardize Aerospace quality expectations on a global level

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

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

Captures aerospace supplements agreed to at an international level

20 February 2001 7

Aerospace Quality System 9100Aerospace Quality System 9100Standard versus ISO 9001Standard versus ISO 9001

9100:1999 added 83 additional and specific requirements to the 20 elements of ISO 9001– 11 amplifications of ISO 9001 paragraphs are

also inserted

Emphasis is placed on Design Control, Process Control, Purchasing, Inspection & Testing and Control of Nonconformances– All areas that have the greatest impact on

safety and reliability for aerospace products

20 February 2001 8

Aerospace Quality SystemAerospace Quality System 9100 versus ISO 9001 9100 versus ISO 9001

4.1 Management Resp. (2)

4.2 Quality Systems (7)

4.3 Contract Review (3)

4.4 Design Control (11)

4.5 Document and Data Control (2)

4.6 Purchasing (13)

4.8 Product Identification and Traceability (2)

4.9 Process Control (13)

4.10 Inspection and test. (10)

4.11 Control of Insp., Measure & Test Equipment (3)

4.12 Inspection & Test status (2)

4.13 Control of Nonconforming Product (7)

4.14 Corrective and Preventive Action (2)

4.15 Handling, storage, package, preservation and delivery (1)

4.16 Control of Quality Records (1)

4.17 Internal Quality Audits (2)

4.18 Training (1)

4.20 Statistical Techniques (1)

Aerospace added Requirements (#)

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ISO 9001:2000 QUALITYISO 9001:2000 QUALITYSTANDARD REVISION IMPACTSTANDARD REVISION IMPACT Released in US, EUROPE & JAPAN 1999

• International Writing Team reconvened March 2000 to begin work on ISO 9000:2000 incorporation

• Work is almost complete, planned release for standard based on ISO 9000:2000 would be mid 2001

• 9100:1999 & 9100:2001 would co-exist until Nov. 2003DEC. 2003

ISO 9001:1994

2000 2001 2002 2003

ISO 9001:2000

9100 : 1999

9100 : 2001

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

Aerospace unique requirementsare not changed in new version of9100– ISO 9000 revision now has requirements

desired by industry, eliminating somerequirements from 9100:1999 version

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

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

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9100 Checklist - 91019100 Checklist - 9101

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 Registrars when performing 9100 audits

Optional scoring feature Purchase of 1 copy from SAE

will give rights to make unlimited copies for eachsite that purchases

20 February 2001 12

9110 Repair Station Quality9110 Repair Station Quality System System

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

145 requirements

• Corresponding 9111 checklist has also been developed and published

•International harmonized version for is being worked

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9120 Distributor Quality System9120 Distributor Quality System

EN 9120 developed and implemented in Europe for “pass through” distributors that broker or distribute parts and supplies that are used in aerospace products– Checklist 9121 is also available

in Europe– Based on 9100, but only applies

necessary system requirements.– Americas already has several

distributor standards (ASA 100, AS7103)– International harmonized standard is being worked

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 approvalManagement System approval approachesapproaches

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 informationinformation

Basic structure of the systemBasic structure of the system International Aerospace 3rd Party Accreditation International Aerospace 3rd Party Accreditation

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

Process plan for Process plan for development/implementationdevelopment/implementation

Describe Describe the systemthe system

Get Get acceptanceacceptance

Communicate Communicate the systemthe system

Implement Implement the systemthe system

•document sector schemesdocument sector schemes•define elementsdefine elements•compare regional schemescompare regional schemes•analyse gapsanalyse gaps•establish equivalence + establish equivalence +

harmonisationharmonisation•amend Sector schemesamend Sector schemes•document international document international

schemescheme

•obtain sector/IAQG obtain sector/IAQG

acceptanceacceptance•advise authoritiesadvise authorities•obtain Accreditation obtain Accreditation

bodies agreement (IAF)bodies agreement (IAF)•Establish a single IAQG Establish a single IAQG

procedureprocedure•Final update Sector Final update Sector

schemesschemes

•to Accreditation Bodiesto Accreditation Bodies•to Registrars/Certification to Registrars/Certification

BodiesBodies•to the Regulatory to the Regulatory

AuthoritiesAuthorities•to OEM’s & Trade to OEM’s & Trade

AssociationsAssociations•to suppliersto suppliers•to the International to the International

communitycommunity

ISSUE DOCUMENTSISSUE DOCUMENTS

•Establish IAQG control mechanism

•establish Sector control mechanism

•approve ‘a’ registrar and‘an’ auditor

•install register(s) of Registrars and Aerospace auditors

•set up data exchange•run the system•monitor and maintain progress

September 2000September 2000 December 2000December 2000 1st Q 20011st Q 2001 2nd Q 20012nd Q 2001

Audits and ApprovalsAudits and Approvals

And what would weAnd what would wedo with all that sparedo with all that spare

timetime

Can you imagine a Can you imagine a world without auditsworld without audits

Like product quality andLike product quality andproject specific requirementsproject specific requirements

We could focus on We could focus on other thingsother things

What a sad place that What a sad place that would bewould be

IMPROVEMENTIMPROVEMENT

20 February 2001 18

9100 Implementation9100 Implementation

Most IAQG Companies are pursuing phased in approach to 9100 most have agreed to put on purchase contract by end of 2001– Many are targeting specific type of Suppliers for application

Some Companies will accept only 2nd Party Approvals– Some will accept 2nd Party Shared Approvals

Some Companies will accept 3rd Party Approvals– Some Accept ISO 9001 Certification with 2nd Party audits of

9100 or elements

– Some are using 9100 approval as a means for Risk Reduction for 2nd Party Audits

FAA has issued Order 8120.12 use of “Other Parties”

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Certification / RegistrationCertification / Registration

“Other Party” Plans being developed for Certification processes– SBAC procedure TS157 for United Kingdom– SAE AIR5359A for Registrar approval for use by AAQG

member companies• AIR5493 - Auditor training requirements

– AAQG / EAQG / JAQG to prepare and present procedures

for cross evaluation by others (for international use)

2nd Party shared process– AECMA - EASE is being used in EUROPE– Expanded AECMA - EASE being consider for worldwide

use

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AIR5359AAIR5359AImportant ConsiderationsImportant Considerations

Includes requirements for OEM’s to share audits Includes requirements for auditors

– Training requirements are in AIR5493 Includes requirements for reporting results of

audits Includes minimum audit times and guidelines Para 9.8 Industry involvement

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

– Must report problems with Registrars– Should track suppliers vs. Registrars vs performance

20 February 2001 21

AS9100 ImplementationAS9100 Implementation(Americas Companies)(Americas Companies)

2nd Party - Customer Shared Audits

– SAE AIR5359A has sharing plan built-in– Customer can ask if Supplier wishes to participate– Auditors must meet requirements in AIR 5359A– AS9101 Checklist and AIR5359A report must be

used and results left with the Supplier– Supplier is then free to offer a copy of results to

any other customer– Results may be used in-lieu of an audit or to

reduce the amount and intensity of an audit

20 February 2001 22

AS9100 ImplementationAS9100 Implementation(Americas Companies)(Americas Companies)

Controlled “Other” Party Plan– AAQG is implementing SAE AIR 5359A document– AIR 5359A is approved & awaiting publication– AAQG is working directly with Accreditation Bodies

to approve Registrars and Auditors– 21 Registrars (150 auditors) submitted by RAB have

been Accredited to AS9000– 2 Registrars (and 14 auditors) are Accredited to

AS9100 at this time. More are expected soon– Japan is implementing a similar system to AIR 5359A– Europe is planning a variation on the same theme– UK has implemented a compatible scheme

20 February 2001

9100 Registration9100 RegistrationAttributesAttributes

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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Single Global ProcedureSingle Global Procedure

Based on SAE AIR 5359ABased on SAE AIR 5359A

Embraces all of the key criteriaEmbraces all of the key criteria

UtilizesUtilizes generic acronym 9100 generic acronym 9100

It is a 2nd / Other party schemeIt is a 2nd / Other party scheme

Includes Registrars and Certification BodiesIncludes Registrars and Certification Bodies

Sector Management Structure (SMS)Sector Management Structure (SMS)

Minimum summary dataMinimum summary data

Contains minor sector variantsContains minor sector variants

The document has sub-team agreementThe document has sub-team agreement

RGM/TS/10073RGM/TS/10073

Tomorrow’s world - on our wayTomorrow’s world - on our way

International AerospaceInternational AerospaceSupplier Quality SystemSupplier Quality SystemEvaluation/CertificationEvaluation/Certification

Active Industryparticipation

ApprovedAerospaceAuditors

Oversight/control Oversight/control by IAQGby IAQG

and Sectorsand Sectors

Inter-NationalInter-NationalAviation AuthorityAviation Authority

endorsementendorsement

One audit One audit accepted byaccepted byall Primesall Primes

ApprovedCert. Bodies&

Registrars

Single global standards

AS/EN9100

Inter-National Accreditation

control

Harmonised systemsof application

Data easily Data easily available to allavailable to all

participantsparticipants

GlobalGlobalacceptance byacceptance bysupplier basesupplier base

SummarySummary A single 9100 Aerospace standard A single 9100 Aerospace standard

An agreed single International procedure of applicationAn agreed single International procedure of application

Sector scheme procedures harmonised and completeSector scheme procedures harmonised and complete

Individual sector launch plans confirmedIndividual sector launch plans confirmed

Implementation planned progressively during 2001Implementation planned progressively during 2001

Establish a mechanism for data exchangeEstablish a mechanism for data exchange

International auditor training and qualificationsInternational auditor training and qualifications

Communication to Authorities and Registrars continuesCommunication to Authorities and Registrars continues

No major barriers to implementationNo major barriers to implementation

Team will co-ordinate implementation programsTeam will co-ordinate implementation programs

Monitor and maintain progressMonitor and maintain progress

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

WWW.SAE.ORGSociety of Automotive Engineers

400 Commonwealth Drive

Warrendale, PA 15096-0001

20 February 2001 28

QUESTIONSQUESTIONS