An Aeronautics Suppliers viewpoint

INTERTECHNIQUE

INTERTECHNIQUE
within
the quality aerospace environment

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 0.1

Summary
Intertechnique Company brief presentation
Quality system requirements
By Official Authorities
By Customers
Types of scoring

Audits
By Customers and Official Authorities
Internal audits (quality system, product audits)

Other fields
Quality questionnaires and surveys
Quality tools
Accompanying documents

Conclusion
I.A.Q.G., 26th-29th June 2001 in Berlin
INTERTECHNIQUE

G. Dion/IAQG - 11/06/01 0.2

INTERTECHNIQUE

Presentation
of
Intertechnique

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.1

ZODIAC Group :

Presentation of Intertechnique
AIRCRAFT SYSTEMS

Fuel systems, oxygen systems,

hydraulic systems.
Electrical systems.
Systems management.
Lighting, flight deck controls and
displays.

5 business segments

AERO SAFETY SYSTEMS

AIRLINE EQUIPMENT

Emergency evacuation systems.

Passenger seats.
Cabine equipment
(trash-compactors systems,
galleys).

TECHNOLOGY

Deceleration systems.
De-icing cells systems.

MARINE LEISURE
Marine.

Telemetry.
Computer-Aided
Telephony.

Swimming
pools.
Leisure.

Airbags.

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.2

Presentation of Intertechnique
ZODIAC in 2000
Sales breakdown
Aircraft systems

27 %

Airline equipment

25 %

Aero safety systems

15 %

Derived technologies

9%
24 %

Marine Leisure
Financial highlights
Zodiac Group Manpower

INTERTECHNIQUE

1 400 M$
9 615 people
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 1.3

Presentation of Intertechnique

Presentation of Intertechnique

INTERTECHNIQUE

Core Businesses

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.4

Presentation of Intertechnique
Fuel Systems
On ground refuelling
equipment and systems

Formula I race cars

refuelling systems

Systmes de gestion de
carburant

In-flight refuelling
equipment and
systems

On board fuel circulation

systems

In-flight refuelling
pods

Man-machine
interfaces

Couplings and control

equipment for aircraft-fuelling
systems

indicators,
control units and
panels

Fuel boost and

transfer pumps,
fuel jet pumps

Equipment for fuel, air

and hydraulic circuits :
Refuelling ports,
valves . . .

Refuelling units
Aircraft Fuel System Test Bench
Locations

Intertechnique at Plaisir and Roche-La-Molire - (France)

IDC Aerospace at Milwaukee (Wisconsin, USA)

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.5

Presentation of Intertechnique
Systems Monitoring and Management
Fuel management systems

Air management systems

Gauging

Bleed air monitoring

Hydraulic systems

Level sensing

Air temperature control

Circuit breakers

Flowmetering

Cabin pressure control

Window heat controllers

Monitoring and control

Monitoring and
Measurement sensors
level sensing :
thermistors, float
Flowmeters

control
Man-machine
interfaces

Actuators
electrovalves
ram air door actuators

computers

Indicators,
control units and
panels

Location
Intertechnique at Plaisir

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.6

Presentation of Intertechnique
Oxygen and Life Support
ERGONOMICS, PHYSIOLOGY

Respiratory protection for

pilots, passengers and
crew members

Storage, regulation and

oxygen instrumentation

Pilot protection
(accelerations, hypoxia,
NBC, noise ...)
quick donning
masks

Liquid and gaseous

oxygen tanks
anti-smoke protective
breathing hood
Regulators

Passenger oxygen
drop out module

anti-g Valves

NBC hood
Location
Intertechnique at Plaisir

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.7

Presentation of Intertechnique
General information
Locations
PLAISIR (France)
ROCHE-LA-MOLIERE

Activities
Fuel systems

(France)

INTERTECHNIQUE (Aerospace) Ltd (Great Britain)

Systems management

IDC Aerospace (Milwaukee, Wisconsin, USA)

Fuel, air, hydraulics,

electrical distribution, optronics

IN-EROS (Fullerton, California, USA)

IN-ASIA (Hong Kong, China)

Oxygen and life support

Manpower : 890 people
Turnover : 1 100 MF (150 M$)

Chairman and CEO : E. MARCHEGAY

Deputy CEO : J.P. BRILLANT

References
Airbus family, Agusta, Alenia, ATR, Bell, Boeing,
Bombardier Canadair, Casa, Dornier, Eurocopter,
Falcon, Gulfstream, Jetstream, Mirage, Rafale, Saab,
Sikorsky.

Quality Vice President : Guy DION

Department Vice-Presidents : J.F. HIGOUNET
J.P. LIBIS
J.M. MATHEY
Marketing and sales, Vice-President : M. KNAFO

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 1.8

INTERTECHNIQUE

Quality System
requirements
Acronyms
Certifications timetable
From Official Authorities
From Customers
Types of scoring

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.

Quality system requirements

Acronyms
AECMA-EASE

(European Aerospace Supplier

Evaluation)

Association affiliated with AECMA

(European Association of Aerospace
Industries),
composed of members from 5 "Regions" : North
(Denmark, Finland, Norway, Sweden), East (Germany,
The Netherlands), South (Italy, Spain, Portugal), Centre
(Belgium, France), West (United Kingdom, Ireland)

BVQI

(Bureau Veritas Quality International)

Certification body.
Chinese civil aviation authority.

CAA

French military official authority.

DGA

(Direction Gnrale de l'Armement)

DGAC / GSAC

(Direction Gnrale de l'Aviation Civile / French civil official authority.

Groupement pour la Scurit Aviation
Civile)

FAA

(Federal Aviation Administration)

US official authority.

JAA

(Joint Aviation Authorities)

European official authority.

QUALIFAS

(Qualit des Approvisionnements pour

les Industries Franaises
Aronautiques et Spatiales)

Central Region of AECMA-EASE.

TCCA

(Transport Canada Civil Aviation)

Canadian civil official authority.

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.0

Quality system requirements

Certifications timetable
Certification

Bodies
BVQI
ISO 9001
AQAP-110

BVQI
ISO 9001
(issue 2000)

Plaisir & RLM

Plaisir & RLM

Customers
QUALIFAS

QUALIFAS

RG Aro 000 83 RG Aro 000 83

RLM*

Plaisir

Military

Official

AECMA-EASE
EN 9000-1

AECMA-EASE
EN 9100

Plaisir & RLM

Plaisir & RLM

Authorities

DGA
AQAP-110
Plaisir & RLM

Civil
DGAC
JAR 145

FAA
FAR 145

Repair Station

Repair Station

1993

1994

1995

Official Authorities

1996

DGAC
JAR 21

CAA
CCAR 145

Production
Certification

Repair Station
Certification

1997

1998

1999

2000

2001

2002

(*) RLM = Intertechnique Roche-la-Molire site

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.1

Quality requirements from Official Authorities

Company Quality Certifications (by

Quality System Quality System Civil Equipment
All activities
Military activities
Production
BVQI

ISO
ISO9001
9001

n 62642
n 62642
of 12/1999
of 12/1999
(Expiry : 12/2002)
(Expiry : 12/2002)
Quality Manual
& Procedures

Audits performed
every 6 months
by BVQI

Renewal
every 3 years

DGA/BVQI

AQAP
110
AQAP
110
n 62642
n 62642
of 12/1999
of 12/1999
(Expiry : 12/2002)
(Expiry : 12/2002)

Quality Manual
& Procedures

Audits performed
every 6 months
by BVQI

Renewal
every 3 years

INTERTECHNIQUE

JAA/DGAC

JAR
JAR21
21
n F.G.005

n F.G.005
of 12/1997
of 12/1997
(Expiry : 12/2001)
(Expiry : 12/2001)

Production
Organization
Exposition (POE)
& Procedures

Audits performed
by GSAC
(6 per year)

Renewal
every 2 years

Official Authorities or Certification Bodies)

Civil Equipment - Maintenance

JAA/DGAC

FAA

(Europe)

(USA)

JAR
145
JAR
145
n F060

n F060
of 12/1993
of 12/1993
(Expiry : 12/2001)
(Expiry : 12/2001)

Maintenance
Organization
Exposition
(MOE)

Annual audit
performed by GSAC
in Plaisir, Orly &
Roche-la-Molire

Renewal
every 2 years

FAR
FAR145
145
n I6QY965J

n I6QY965J
(Plaisir)
(Plaisir)
n I4QY966J
n I4QY966J
(Roche-la-Molire)
(Roche-la-Molire)
of 07/1995
of 07/1995
(Expiry : 07/2001)
(Expiry : 07/2001)
MOE
+ US
supplement

Annual audit
performed by FAA
in Plaisir &
Roche-la-Molire

Renewal
every year

TCCA (Canada)
CAA (China)

Recognition of
Recognition of

JAR
JAR145
145

n TCAC 897-30
n TCAC 897-30
of 12/1997
of 12/1997
(Expiry : 02/2002)
(Expiry : 02/2002)

CCAR
145
CCAR
145
n F.3516
n F.3516
de 07/1998
de 07/1998
(Expiry : 12/2001)
(Expiry : 12/2001)
MOE
+ Canadian &
Chinese
supplements

Annual self-evaluation
report to be provided
to Chinese Authorities

Renewal :
Canada : every 2 years
China : every 3 years

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.2.1

Quality requirements from Official Authorities

Company Quality Certifications
(by Official Authorities or Certification Bodies)

Military Aviation Authorities : Requirements based on ISO 9001 J

Civil Aviation Authorities : Specific requirements L
JAR 21 Production certification :
Mutual recognition from FAA and DGAC J
Product certifications : JTSO, TSO J
Maintenance certification :
FAA / DGAC : turnover FAR145 J
(FAR 145 survey by DGAC)

CAA (China) and TCCA (Canada) certifications (audits and supplemental costs) L

Certification Body (BVQI)

Today : ISO 9001 & AQAP-110 certifications
Next future : AS/EN 9100 assessment ?

INTERTECHNIQUE

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G. Dion/IAQG - 11/06/01 2.2.2

Quality requirements from Customers

Customers audits, results and approvals
AUDIT FIELD

CUSTOMER
QUALIFAS
AECMA-EASE
BOEING

QUALITY

AIRBUS UK

MAINTENANCE

EN 9000-1 *
D1-9000 rev. A *
EFQM model

Result

Comments

19,2 / 20

New standard
EN 9100 *

7,8 / 10

New standard
BQMS (AS 9100) *

"Silver" level

BAe/AG/QC/SC1 *

No scoring

BOMBARDIER
CANADAIR

QD4.6-40 *

No scoring

LIEBHERRAEROSPACE

LTS-AQ-INS-06-0032 *

18,9 / 20

SAAB

80-V-10.1E

89 / 100

GULFSTREAM

SQAR 0001

No scoring

SYSTEM
AUDITS

Standard

AIRBUS INDUSTRIE

EN-9110 *

New : AUK/SA/001-3 *

New : LTS-AQINS-06-0276 *

16,4/20

QUALITY
SYSTEM

FEDEX, DHL, SAS

CASE (North America)

No scoring

* : documents based on the ISO 9001 standard

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.3.1

Quality requirements from Customers

Customers audits, results and approvals
Quality System : Harmonized requirements J
in France : through QUALIFAS
in Europe : through AECMA-EASE
At the international level : through IAQG

RG.Aro 000 83 in 1994

EN 9000-1 in Feb. 1999
AS/EN 9100 in Feb. 2001

Maintenance activities : Requirements to be harmonized L

EN 9110 (every 3 years) (applicable in Europe since 2001)
CASE (every 2 years)

Scoring : Quality System scorings to be harmonized L

Several quality system scoring methods (6 for Intertechnique)
Scoring is an incentive element for improvement : it enables to rate the
progress achieved

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.3.2

Types of Scoring
Several levels of scoring
with various calculation methods
Quality System
Examples :
../20, ../10, ../100, Approved / Not approved

Delivery indicators
New products or repairs
% delivered on time, delayed deliveries, TAT,

Product quality
Examples :
Rejection rates, QN, R1, R2, IF, IE

Overall scoring
Examples :
E NCC, IP, Q100, quartiles, Gold/Silver/bronze

Expected objectives
A simple calculation method
Indicators to be easily understood by the General Management of companies
Indicators jointly checked by the customer and the supplier

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 2.4

INTERTECHNIQUE

Audits

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 3.1

Quality system audits

performed by Customers / Authorities at Intertechniques

Audits

(Products audits not included)

JAR 21

25
23

AQAP 100
19

20

18

15

15

14
13

13
13

12

13

10

12

11

11

12 Civil Authorities
11 Customers

10

10

10

8
5

5
BVQI

1
1

0
1993

1994

70

1995

1996

64

1997

51

50

40

2000

2001

55
47

44

Total duration (days)

41

49
44

40

30

1999

Substantial
quantities of audits

61

60
40

1998

0 Military Authorities

35

29

Total quantity of audits

31

20
10

22

25

1999

2000

Audit periodicities
linked to the
certifications
Decrease trend

0
1993

1994

1995

INTERTECHNIQUE

1996

1997

1998

2001

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 3.2

Audits
Quality system audits
performed by Customers / Authorities at Intertechniques
(Products audits not included)

Expected objective :
1 quality system audit every 3 years based on the international aerospace
standard, performed either by customer association or certification body

What may allow customers to concentrate their efforts on

other audits :
Logistics (management or customer orders, follow-up of delivery dates; purchase control ;
cost management ; leadtime control, )
Product audits (FAI, Source Inspections, )

Process audits (EMPI, EMPF, )

Design reviews (PDR, CDR, )

To give a greater importance to internal audits :

Self-assessment : more motivating
Best conditions to set up improvement actions
INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 3.3

Audits
Internal quality system audits
140
115

120

92,5

100

85

82,5

100

Total duration (days)

104

80
50

60

Total quantity of audits

37,5
40

46
33

20
15

20

1993

1994

37

34

1997

1998

50

52

1999

2000

0
1995

1996

2001

Quantity of audits : increase trend

Audit duration : shorter (since 1999) :
using check-sheets, (41 audit check-sheets for system and process audits)
standardising the minutes,
improving the corrective action follow-up

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 3.4

Audits
Internal products audits
Products Audits Quantity
FAI Quantity

250
200

200
150

139

150

41

46

38

100

154
98

50

112

0
1998

1999

2000

FAI (First Article Inspection)

performed at the beginning of serial production or for equipment changes
(the quantity depends on the quantity of new products)

Products audits
Performed on equipment in production
(the quantity depends on the quantity of product families)
INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 3.5

INTERTECHNIQUE

Other fields

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 4.1

Other fields
Answers to customers quality questionnaires and surveys
Answers to quality questionnaires + certificates
Quality certificates only dispatching

106

120
100

70

47

80
60

41

18

40
20

8
10

59
29

0
1998

1999

2000

Necessary standardisation of the answer process

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 4.2

Other fields
Quality Tools
Tools often recommended by the customers, sometimes mandatory :
Self assessment (EFQM model) E
6 Sigma
Lean Manufacturing
Key characteristics
Fracas
HALT, HASS

Do not require, but promote their implementation

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 4.3

Accompanying Documents

Other fields
or
F
A
JA

n
O
m

orm
F
A
FA

/DC ote
L
B yN
er tion
v
i
l
De clara ance
De mpli
Co
of

in e
h
C

se

INTERTECHNIQUE

ag
T
llow
e
Y

ag
T
w
o
l
l
Ye

ic a
f
i
t
r
Ce

03
1
8

te
Lo

ard
C
g

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 4.4

Quality tools : E.F.Q.M. Model Self-assessment

1999

Reminder - Schedule

BAe

BAe

1998
CIP 4th issue
Nov.

CIP 3rd issue

May

BAe

BAe's review
Filton
Nov. 30

BAe's review
Plaisir
May 6

1997
Internal training
Sept./ Oct.
CIP 2nd issue
Feb.

BAe
CIP 1st issue
Sept.

E
External
ASSESSMENT
Dec. 1-4
On site training
(E.F.Q.M.
General
trainers)
Management
Oct. 16-17
Committee
Sept.
GREEN BOOK (Self(decision)
assessment book)
1st issue : Nov.

Plenary Meeting
June 22
General
Management
Committee July

BAe's review
Filton
Sept. 4

CIP 1st and

2nd drafts
March/April

IMPROVING OURSELVES

PREPARING THE ASSESSMENT

INTERTECHNIQUE

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G. Dion/IAQG - 11/06/01 4.5.1

Quality tools : E.F.Q.M. Model Self-assessment

Reminder - Schedule

Self
Assessment
Business Units
Seminaries

2000
Airbus UK

AIRBUS
UK's
review
Plaisir
Aug. 30

Airbus UK

CIP
Assessor
5th
Training
issue
(Brussels)
Feb.
Jan. 1112

CIP
6th
issue
May

AIRBUS UK s
review
Plaisir
Mar. 6

CIP
7th
issue
Aug.

Airbus UK

2001

EFQM
Booklet
issue
Oct.

EFQM
Internet
Site
Sept.

D7
Feb.
26-27

Self
Assessment
GM Committee
Seminary
Nov. 20-21
D4
Feb.
6-7

AIRBUS
UK's Review
Filton
May 22

IN-S
March
29-30

D2
March
12-13

IN CIP
issue
April

Revised
Green
Book
issue
May

IN CIP
Review
Nov.

Self
Assessment
Launching
Meeting
Oct
IMPROVING OURSELVES
ORGANIZING SELF ASSESSMENTS

PREPARING SELF ASSESSMENT

IMPROVING OURSELVES

INTERTECHNIQUE

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G. Dion/IAQG - 11/06/01 4.5.2

INTERTECHNIQUE

Conclusion

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 5.1

Conclusion
Consequences
to the Intertechnique Quality Organization
Quality System staff
0,5 person in 1995 Today : 3 people
General documents and Standards
Complexicity of the document management
(Quality Manual, Production Organization Exposition, Maintenance
Organization Exposition, Inspection Procedure Manual, )
Procedures (Quality Intranet)

High quantity of external audits

Repetition of the same audits (some departments are audited several times
per year)

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 5.2

Conclusion
Our reflections
Quality System
May be unique and can cover 90 % of the requirements from :
Civil Authorities / Military Authorities / Certification Body / Aerospace Customers
ISO 9001 and international standard AS/EN/SJAC 9100 must be fully deployed
Scoring is a progress factor
Simplification
Concensus
Self-assessment is the basis of the continuous improvement
To be promoted, but not be imposed by customers
Focus on products and processes
Any new requirement setting-up should be done only after consultation of the
supply chain

INTERTECHNIQUE

I.A.Q.G., 26th-29th June 2001 in Berlin

G. Dion/IAQG - 11/06/01 5.3