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MANAGEMENT SYSTEM
STANDARDS - AS 9100 SERIES
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HISTORY OF 9100
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Background - Early to mid-1990s
Quality
Assurance
Management
(Manufacture In Quality)
Quality
Assurance ISO 9001,2,3
(Inspect In Quality
In Process)
1980s-end 90s
Quality MIL-Q-9858
Control 1960s-80s
(Inspect In Quality
at end of line) Regulations
(FAA, JAA, ESA, etc)
MIL-I-45208 Customers Specific
1940s-60s Requirements
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Background - Early to mid-1990s
z DOD (US Department of Defense) canceled quality
system specifications (MIL-Q-9858)
z FAA (Federal Aviation Administration) lacks a
definitive description of a quality system (FAR 21 &
FAR145)
z Defense Customers and Aerospace Primes (mainly in
Europe) began to flow ISO 9000 series plus unique
requirements to suppliers
z Suppliers asked industry to standardize
Needed to operate a single quality system
Already adopting ISO 9000 series
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U.S. Industry Response - 1995
Sponsors
Aviation/Space & Defense Division of
American Society for Quality
SAE Aerospace Council
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Aerospace Industry Agree:
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Aerospace Standard birth
D1-9 C
Spec ompany
Inputs 000 ific R
eqm
00 1 N ts
-I
O- 9 M A
FAA IL-Q SA
IL
I S
DoD
M
AS9100
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Global Quality Standard Activity
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A Global Organization
AAQG
(Americas)
EAQG
APAQG
(Europe)
(Asia)
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AEROSPACE SUPPLY CHAIN
Tier 1
9100 Vehicle / Airframe /
9110 for
Propulsion Manufacture
Repair
Variation Reduction
Stations
FAI
Tier 2 Process Proving
Integrators /
Source Control/
Software Dev./
Major Assemblies
Tier 3 - Integrators /
Source Control / Specialty
Electronics / Wiring / Compnts
s e s
ces
9120
Tier 4 - Make to Print / Machine Shops
Pro
/ Processors
ia l
Tier 5 - Distributors (Fasteners, Raw Materials,
e c Company
Sp
Commodities, Adhesives, Special Materials)
Specific or
Tier 6 - Raw Materials (Castings, Forgings, Sheet, etc) NADCAP
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Aerospace Quality Standards
Numbering System
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Aerospace Quality System
Standards
z INTERNATIONAL STANDARDS
9100 - Quality System for Aerospace
Manufacturers
9101 - Check sheet for 9100
9110 - Quality System for Aerospace Repair
Stations
9111 - Check sheet for 9110
9120 - Quality System for Distributors
9121 - Check sheet for 9120
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Aerospace Quality System 9100
Standard versus ISO 9001
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9100 Specifics (where ISO
9001 implies 9100 requires)
ISO 9001:
z Generic quality management system standard - applicable to
shoes as well as to airplanes
9100:
Continuous Improvement:
z Continuous improvement processes shall include provision for using the quality
policy, quality objectives, audit results, measurement and analysis of data,
variability reduction, corrective and preventive action, and management review
(all but variability reduction are part of 9001:2000 requirements)
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ISO9001 versus 9100
z 9100 version is formatted to match ISO 9001:2000 and added
requirements that provide for -
Regulatory organizations interfaces
Configuration Management
Design and Development V& V., & V&V testing
Control of changes in Production Process
Control of production equipment, tools, NC machines
Control of work in outside facilities
Control of service operations
First Article Inspection
Inspection documentation
z These added requirements enables a standardized approach to
supplier flow down requirements
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9100: Quality Management
Systems (ISO Clause 4)
z Requirements of regulatory authorities must be
included in documentation
Including access by authorities to the records,
documentation and change approval (as reqd)
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9100:
Product Realization (ISO Clause 7)
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9100:
Product Realization (ISO Clause 7)
z Purchasing
Responsible for all suppliers (incl. customer
designated ones)
Must have a list of suppliers
Supplier performance review process
Control of special process sources
Whoever approves a supplier, can disapprove them as
well
Stringent flow down requirements - sub-tier
Notification of nonconformance / process change
Right of access by customer and regulatory personnel
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9100:
Product Realization (ISO Clause 7)
z Planning for Production and Service:
Control plans and process controls
In-process verification for hidden features
Design of tooling for variable measurements
z Controlled Production
accountability of product during manufacture
evidence all operations are complete
FOD control
monitoring of environmental influences
criteria for workmanship
Use of approved data and specified tooling with
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9100 Special Process Requirements
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Special Process Approval Objectives
z To put in place industry controlled process for meeting
requirements of 9100 clause 7.5.2
Supplier processes are an extension of the OEM
processes
z To reduce redundant audits for the special process at
suppliers and improve the global quality level
Common requirements (auditors and audit
questionnaires)
Harmonized assessment process
Data exchange
Demonstrated industry managed process
Process oversight
Mutual system recognition
NADCAP/ASD PRO
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9100 Introduces Two important
Concepts for Aerospace
z First Article Inspections
Always required
9102 is mentioned for Guidance
9102 is only mandatory when specifically
required in contracts
z Key Characteristics
When specified
9103 is referenced for guidance
9103 is only mandatory when specifically
required in contracts and key characteristics
are identified
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9102 First Article Inspection
z FAIs apply:
to assemblies and all levels of parts
within an assembly, including castings
and forgings
Suppliers responsible for ensuring that
characteristics conform to Customer
requirements
Sub-tier suppliers and processors of
parts and materials for suppliers
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What is Included in First Article
Inspection?
z Verification of All Design Characteristics:
Dimensional Verification via Marked-up (or Ballooned) Drawings
that Correlate Characteristic Number from FAI to the Drawing.
Part Marking
z Material and Special Process Certifications
Including Operator Certifications (e.g. NDT, Welding)
z Manufacturing Process Verifications
Manufacturing Routing Sheets.
Referenced Exhibits Supporting the FAI (e.g. CMM Data Printouts,
Test Data, Acceptance Test Procedures, Process Certifications, etc.).
Process Capability Studies, As Applicable.
Gauge Correlation, As Applicable.
Tooling Traceability, If Tooling Is Used to Verify Design
Characteristics
z Nonconformance Resolutions
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9102 First Article Inspection
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9103 Key Characteristics
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Variation Management of Key
Characteristics Purpose (9103)
Understanding processes
Using appropriate tools
Demonstrating acceptable process capabilities
Guidelines for reporting process capability data
to primes.
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9100 Checklist - 9101
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9110 Repair Station Quality
System
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9120 Distributor Quality System
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Industry Leaders are Listening
z Agreed to improve the overall approach to quality
z Major Aerospace Companies have agreed upon Quality
Management System approval approaches
z A key objective is to reduce the number of audits
z There are significant benefits to the Aerospace Industry
z Working to develop our International processes to
incorporate the new approach
z International approach is based on a single agreed
standard, harmonization of system application and shared
information
Summary
z A single 9100 Aerospace standard
z An agreed single International procedure of application
z Sector scheme procedures harmonised and complete
z Implementation planned aggressively during 2005
z Establish a mechanism for data exchange
z International auditor training and qualifications
z Continue to communicate to all
z Team will co-ordinate implementation programs
z Monitor and maintain progress
QUESTIONS
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