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Industry Controlled Other Party (ICOP) Supplier Certification and Oversight

Stan Adachi – Director, Supplier Quality

Boeing Defense Space & Security

CQSDI - March 2010

Briefing Topics

� IAQG – International Aerospace Quality Group

� Industry Controlled Other Party (ICOP)

� IAQG Other Party Management Team� IAQG Other Party Management Team

� Industry Call for Action

� Boeing Oversight

� Summary

International Aerospace Quality GroupInternational Aerospace Quality Group

IAQGCouncil

General Assembly Forums

� Aerospace Quality Management Systems Standards

IAQG at a Snap Shot

SECTORS

EAQG(Europe)

AAQG(Americas)

Standards

� Manage Industry Controlled Other Party (ICOP) processes

� Share best practices

� Harmonize with regulatory and government agencies and other stakeholders

APAQG(Asia & Pacific)

The Premise

A healthy and robust Quality Management System is the foundation to drive first time Quality, Deliver y, and Cost on all products and services throughout

the value stream

Industry Controlled Other Party (ICOP)

� ICOP is a globally harmonized Aerospace Quality Management System (AQMS) Certification process defi ned by the IAQG

– Industry Controlled:• The IAQG through each Sector provides direct oversight of all

AQMS certification activities

– Other Party:• Certifications are completed by authenticated Certification

Bodies that are recognized through the ICOP process

� ICOP process is managed through the IAQG’s sub-coun cil, Other Party Management Team (OPMT)

Other Party Management TeamOther Party Management Team

OPMTCommittee

IAQG Council

Mission

Management and oversight of the 9100 series Aerospace

IAQG Other Party Management Team

Sector Management Structures

OPMT(Europe)

JRMC(Asia & Pacific)

RMC(Americas)

the 9100 series Aerospace Quality Management system

certification program.

VisionEnsure that the program is

robust, recognized and valued

Voting MembersABs CBs

Industry

Voting MembersABs CBs

Industry

Voting MembersABs CBs

Industry

ICOP Management Triad

� AS9104-1– IAQG’s involvement

– Sector management structure

– Accredited Certification Bodies

– Authenticated Auditors

– Assessment Criteria

– OASIS database management – OASIS database management

� AS9104-2– Oversight and surveillance process to ensure conformance to established

aerospace industry 9100-series accreditation/certification requirements.

� AS9104-3– A common process for aerospace auditor training and authentication to be

utilized by all the International Aerospace Quality Group (IAQG) sectors.

Other Party Management Team

IAQG/AAQG Engagement

Auditor/ Training Provider Oversight

AB Office Assessments

IAQG Oversight Planning

Industry Oversight

OP Assessor

Industry Oversight

Industry Oversight Factoids

� Certified Supplier Sites– AS9100 10,088– AS9110 243– AS9120 687

� Accreditation Bodies 10

October 2009 Data

AB Witness Assessments

CB Office Assessments

Planning AssessorBOR

OASIS

CB Witness Assessments

� Accreditation Bodies 10

� Certification Bodies 82

� IAQG members participating 41

� Industry Oversight Audits 205

� Average Number of NC’s– Majors 0.2– Minors 2.6

Industry – Call for Action

Other Party Management Improvements Road Map

AS9104/1 BallotDec 2009

AS9104/1rewrite published

July 2010

All audits to new standards

July 2012

AS9104/2 & /3 rewrite published

Jan 2011

IAQGOPMT

SectorsMember Companies

RMC MeetingJan 2008

AAQGMar 2008

IAQGApr 2008

IAQG SWG puts Other Party in

StrategyDec 2008

Dec 2009

Is it Working?Jan 2008

AS9104/1 rewrite startApr 2008

OPMT FMEA

Feb 2008

OPMT FMEA (2008)

� FMEA: (not in order)

– Surveillence Audits

– Corrective Actions (Audit Findings)

– Certification Audits

– Standard Interpretation / Clarification

– CB Operations

– Feedback Process

– Auditor Competency

– Auditor Training 0

50

100

150

200

250

1 2 3 4 5 6 7 8 9

IAQG FMEA – Influence Index

FMEA Results and Improvements

9104/1 Major Rewrite

• Min. Audit Days – No reductions

• Ramifications for poor performance

• Criteria for Multiple Site Certification

• OASIS Improvements & Feedback

9104/3 Revision

• Competency based Auditor Authentication

• Sanctioned Aerospace Auditor Training

Certification Body Operations Auditor Competency

• OASIS Improvements & Feedback

9104/2 Revision

• Additional Witness Audits

• Updated Oversight Tools

• Annual Review and Metrics

9101 Major Rewrite

• Process Approach

• Updated tools

• Audit Guidance

• Corrective Action Requirements

Audit and C/A Effectiveness SMS Oversight of Process

Strengthening Boeing Oversight

� Ensure Industry Oversight processes are healthy

� Boeing’s CB’s are compliant to Industry requirements

� Boeing Oversight– Primary (Industry support)

Boeing Oversight Process

– Primary (Industry support)– Supplemental (Boeing)

� Boeing only IAQG member company that actively performs Supplemental Oversight

� Utilizes risk-based approach tied to CB influence and performance

Other Party Management Team

IAQG/AAQG Engagement

Auditor/ Training Provider Oversight

AB Office Assessments

AB Witness Assessments

CB Office Assessments

IAQG Oversight Planning

Industry Oversight

OP Assessor

BOR

CB Witness Assessments

BOR Process Model and Improvements

Boeing Enhancements

� Added Supplemental BORs (SBOR) Resources

� Tripled number of Oversight Assessments from 2007

� Added new Supplier Quality Surveillance

OPMT / BOR Process Management

IAQG/AAQG Engagement

Auditor/ Training Provider Oversight

AB Office Assessments

AB Witness Assessments

CB Office Assessments

CB Witness Assessments

IAQG / AAQG

Oversight Planning

Boeing

Industry Oversight

OP Assessor

BOR

Technical Review &

Data Analysis -

Effectiveness(Core)

OASIS

Assessments

Results

� # BORs/SBORs 39

� # Boeing recognized CBs 61

� Boeing Supplemental Audits 128

� CB Nonconformance's 101

Surveillance Assessments

Client Validations

CB Audit Report Reviews

Certification Validation

Supplier Surveillance and

Feedback (PQAA & OASIS)

Boeing Supple-mental

Oversight Planning

(Semi-annual)

Supple-mental

OversightBOR or SBOR

SQ Field Ops

Activity Reporting(PQAA & OASIS)

Review & AB/CB

Engagement/Issue

Resolution(Core)

OASIS

Boeing Oversight Process Model

Boeing Oversight Findings

� Findings: (not in order)

– OASIS input & data integrity

– Depth of auditing

– Non-conformance reporting e.g. incomplete, soft gradinge.g. incomplete, soft grading

– Incomplete audit

– Technical Audit problems

– Multi-Site issues e.g. incorrect scope, sites not audited

Boeing Oversight Improvement Results

� Improving CB audit performance

• Reduction in auditor soft grading

• More comprehensive and thorough audits

• Improved corrective actions

� Validated Industry FMEA, but found other areas to improve

� Increased awareness by Certification Bodies of Boeing requirements and expectations

� Sharing information with Industry for continual improvement

� Increased confidence level of regulatory agencies

Summary

� Making progress – supplier feedback indicates audits more comprehensive and thorough

� Continue to utilize Boeing oversight to improve Indu stry practices and Boeing suppliers practices and Boeing suppliers

� Leverage Industry to ensure certification program remains robust, recognized and valued

Thank You