IAY G05 C Part 2

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IAY G 05 C March 2004
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QUALITY MANAGEMENT SYSTEM
REQUIREMENTS FOR SUPPLIERS IAY G 05 B Rev. /
authorization document shall be reported onto the cover “Assembly Inspection Report”
(Attachment 2) in the appropriate item.
Delivery of the Assembly Inspection Report

Two copies of the Assembly Inspection Report (Attachment 2) must be sent as
attachment to the Assy during the shipment; one attached to the Assy and the others
sent by post to the receiving Quality Control unit.
Enclosing documentation
The Certificate of Conformance or the JAA FORM ONE, enclosing and relating the
Assembly Inspection Report, shall be provided.
Alenia Aeronautica Additional Requirements applicable to Class F1 Suppliers
Maintenance of aircraft components according to JAR 145 c/o

Suppliers
Maintenance activities concerning assys/particulars included in the List Of The
Authorized Operations (L.O.A.) concerning Alenia Aeronautica approval according to
JAR 145, must be managed in the world of the JAR 145 approved organization of Alenia
Aeronautica and described in the M.O.E . of Alenia Aeronautica.
A specific “Quality Requirement” for maintenance is included in the reference Purchasing
Order/Contract.
7.1.1.1 Production documentation (No Alenia Aeronautica additional requirement)
7.1.1.2 Control of production process changes (No Alenia Aeronautica additional

requirement)
7.1.1.3 Control of production equipment, tools and Numerical Control

(N.C.) machine programs
Alenia Aeronautica additional requirements applicable to Class C1; C2; C3

Suppliers
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Tooling management c/o Suppliers

Supplier is responsible to verify continuous efficiency of tooling used to realize
Alenia Aeronautica products, to assure a repeatable production process.
As tooling have to be considered:
• Master (Mock-up that defines geometry lines and interchangeability/interface

points).
• Assembly Jigs
• Marking, trimming and drilling template
• Marking and drilling dies and counter-dies
• Stratification and polymerization tools
• Inspection templates and tools
Suppliers activities for tooling management depend from inspections to be performed, in

particular Periodical Inspection (Scheduled) and Non-recurrent inspection.
Periodical Inspection (Scheduled)
Any production and means of compliance tool, used to control dimensional

characteristics, with the purpose to define product conformity (parts/assy) with project
requirements, defined as Media of inspection (M.O.I.), shall be submitted to periodic
inspections according to requirements of Inspection plan developed by the Supplier and
approved by Alenia.
The Supplier is responsible for the carry out of periodic check of production and
inspection tools placed in its plants, either they have been realized by the supplier
itself or they have been supplied by Alenia Aeronautica.
To carry out periodic controls, the Supplier shall prepare a dedicated procedure, in which
the following Supplier activities have to be detailed:
• Periodic Inspection Plan preparing

• Definition of Inspection frequency
• Request to Alenia Aeronautica of Inspection Plan Approval
• Inspections execution
• Inspection certification through the tool marking
• Record retention
• Tolerances on the expiry date of the Periodic Inspection
• Postponement of the inspection
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This Procedure, shall be called in the Quality Plan that will be approved by Alenia
Aeronautica Supplier Quality.
This procedure can also include Non-recurring Inspection.
• Periodic Inspection Plan

If tools are supplied by Alenia Aeronautica or built by sub-supplier itself, the Supplier is
responsible to prepare an Inspection Plan and submit it, before utilizing, for approval to
Quality Control of Alenia Aeronautica Operative Unit that committed the parts.
Inspection plan shall define characteristics that can influence technical and functional
performances of tool, that it is necessary to keep periodically under control.
Therefore it is necessary to identify and define in the Inspection Plan the following item
(this list is to be considered mandatory for Boeing programs):
− Type of inspection to be performed

a. A Type-Inspection:
Visual inspection, to ascertain conservation and wear status of tool or their
components. (holes, bushines, plugs, locks, reference lines, surfaces status and
any other element tool verifiable without the help of drawings and/or
measurement instruments).
b. B Type -inspection:
Inspection to verify surfaces flatness with reference points. It is carried out
using optical instruments. This check requires a previous type A inspection.
c. C Type-Inspection:
Inspection of right equipment co-ordination with check points. It is carried out
using Coordinate Measurement System (teodolite, laser tracker, etc.), master,
layout. This check requires a previous execution of A and B inspection.
− Acceptance criteria
− Frequency of inspection
− Features to check with relative design requirements
− List of tool parts/detail
− Last tool design review
− Leveling requirements
− Visual inspection for damaging or wear
− Temperature of tools during periodical inspection
− Coordinating tools
− Digital measurement features (optical tooling points, indexes, I/R check features,
etc.)
− Tolerance use for periodical inspection
− Scale measurement before and after the inspection (for tools inspected with
teodolite, Laser, etc.)
− Measurement report after possible reworking
− Non conformities /out of tolerance list
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Moreover, document concerning tools used for Boeing programs shall report:
− Boeing tool ID
− Lifetime serial number
• Definition of kind and frequency of Inspection

Definition of the kind of inspection and of its frequency is a Supplier responsibility, it is
based on program specific requirements (if any) and on the following items:
− Project of the tool audits function

− Kind of use and its frequency
− Available historical data about tool performances
− Non-conformity frequency on realized product, that can be referred to tool
anomalies
In any case tools will be submitted to C-type inspection at least a year.
• Inspection plan approval

The Supplier is responsible for requiring the approval of inspection plan, sending them to
Quality Control of Alenia Operative Unit which committed the parts, that will
provide to approve them, or to require necessary changes before the approval.
• Inspection
The Supplier is responsible to plan and perform inspection on tools located to its plant;
the Supplier can use internal sources or can require the intervention of a specialized
external Company.
It is to put in evidence that if it is used a specialized external source, the Supplier is fully
responsible, to Alenia Aeronautica, for the execution and for inspection results.
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• Inspection state by mean of marking of the tool

The Supplier is responsible to provide evidence of the correct application of Periodic
Inspection Plan and of the good result of the inspection. This evidence is provided
through:
− Certification of inspection plan with date and stamp

− Marking of the metallic plate for inspection registration present on the tool itself.
On this plate it is to punch:
o Inspection date
o Stamp of the Quality Control representative who carried out the inspection
o Tool expiry date
The Supplier is responsible for periodical inspection reports record retention. The -
Supplier shall have an updated register of all tools and the status of periodical
inspections.
The state of inspection results during the time shall be considered as basis for the
revaluation of expiry date.
The Supplier has to provide inspection data on Alenia Aeronautica request.
• Tolerances on periodic inspection expiry date

Tolerance on expiry date is 15 days in order to:
− To allow the finishing of an assy already in working

− To carry out the periodic inspection before expiration when it is expected the
beginning of a new working
• Postponement of Inspections
The Supplier, with the necessity of postponing the periodic inspection of a tool, shall
previously ask for a written authorization to Quality Control of Alenia Aeronautica
Operative Unit responsible for acceptance of parts produced by the Supplier, which has
the authority to give or to reject the authorization.
The Supplier can ask for only one postponement for 3 months as maximum.
Authorizations to postponement, duly signed by Alenia Q.C., shall be displayed on the
tool object of postponement.
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Non recurrent inspection
It is to define no-recurrent those inspections that are necessary to carry out in the
following cases:
• Modification of tool design

• Tool damaged (sure or suspected)
• Tool relocation (for fixed tools)
• New start of tool use
It remains a Supplier responsibility the execution of this inspection for which it shall
define adequate procedure in the same way as periodical inspections.
This procedure shall define at least the following activities:
• Inspection Plan
• Alenia Aeronautica approval of Inspection Plan
• Inspection activity
• Certification of inspection carried out through tool marking
If it is not differently agreed with Alenia Aeronautica, execution of this activities is

responsibility, and it will carry out according to procedure before described.
7.1.1.4 Control of work transferred, on a temporary basis, outside the

organization’s facilities (No Alenia Aeronautica additional requirement)
7.1.1.5 Control of service operations (No Alenia Aeronautica additional requirement)
7.1.2 Validation of processes for production and service provision
Alenia Aeronautica additional requirements applicable to Class C1; C2; C3 Suppliers

performing Special Processes for Manufacturing and/or Inspection
Special processes qualification and qualification renewal
General
Manufacturing and Inspection Special Processes, which Alenia Aeronautica requires the
qualification for, are listed in the document 99/NT/0000/N325/A/020159 last applicable
revision. In the same way as Special Processes also the Critical Activities, afterwards
listed, have to be qualified :
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• Wiring manufacturing
• Optical fibers
• Electrical finishes
• Staff assigned to liquid oxygen room
• Outfitting of seats and canopy ejection
• Armourers
• Towed aircraft brakemen
• Explosives handling and transport
• Metrology
• Hydraulic system test
• Engines test
• Parachutes folding
• Refueling
• Ejection seats lock
• Wiring installation
• Master Dimension Data extraction for inspection
• Assembly of fillets
• Pyrometry
This activities require personnel training, qualification and certification.
The list of special processes applicable to the specific work package assigned to the
Supplier shall be indicated in the Quality Plan.
If Alenia Aeronautica is the owner of the special process specification and/or if

Alenia Aeronauticaholds a Customer formal delegation, qualification flow will be
manged by Alenia Aeronautica S.p.A. Supplier Quality Unit, with the support of the
Technology, Processes, Materials and Non Destructive Tests Laboratory.
If Alenia Aeronautica is not the owner of the special process specification and/or if
Alenia Aeronautica S.p.A. does not hold a Customer formal delegation, the
qualification will be initially led with the same modalities in order to verify the supplier's
capacities. Exceeded with positive result the verification phase, the supplier will be
submitted to qualification of the Alenia Aeronautica Customer, which will perform it
with its own rules and will formalize it in its qualification documents.
Alenia Aeronautica, through the O.P.S.P. (Outside Droduction Specification Plan),

identifies the special processes to be applied.
However the Supplier is responsible to check the completeness of the processes, listed
in the O.P.S.P. following the analysis of the applicable drawings.
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If the Supplier is not qualified yet for one or more special processes, it shall ask Alenia
Aeronautica Suppliers Quality dept., through the Procurement Unit, to qualify them.
The main elements of the qualification process are the following:
• Process qualification;
− plants and equipment qualification
− designed personnel qualification (see paragraph 6.2.2)
• Maintenance of the Qualification Conditions
− periodical inspections
− maintenance of plants/equipment
• Renewal of qualification
• Loss of qualification
• Process-Plants/Equipment qualification
A special process may require the qualification:

− of plants/equipment and designed personnel
− of plants/equipment only
− of designed personnel only
NOTE: For qualification of designed personnel, see paragraph 6.2.2 of this document as
Alenia Aeronautica additional requirement.
The Supplier, for each special process to be qualified, shall provide the Alenia
Aeronautica Supplier Quality dept. with:
• the Qualification Plan, containing the schedule of the activities which are necessary
for the qualification;
• the Technical Report, using the model in Annex 3 (the Supplier can use any alpha-
numerical code provided by its Quality System);
• A test specimens kit according to applicable specifications, which the Alenia
Aeronautica Laboratory may test .
• The testing operative procedures concerning Special Inspection Processes (NDT)
must be submitted to approval of a III Level Professional accepted by Alenia
Aeronautica and/or its Customers. The Supplier can also ask for Alenia Aeronautica
III Level Professional; in this case, the Supplier shall request this to Alenia
Aeronautica S.p.A. Procurement Unit which activates the competent
Technical/Commercial Unit.
NDT Procedure Approval

NDT Procedure Cover Page shall indicate:
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• Name of NDT III Level accepted by Alenia Aeronautica

• Identity Code of NDT III Level accepted by Alenia Aeronautica
• Procedure Edition/Revision
• Approval date
• Signature of NDT III Level accepted by Alenia Aeronautica III Level Signature
Whenever the Procedure will be updated, the NDT III Level accepted by Alenia
Aeronautica shall release a new approval on the Procedure Cover Page. Alenia
Aeronautica, during the audit for renewal of qualification, will verify that the NDT
Procedures are approved by III Level.
Supplier Quality Unit, together with Material & Processes Unit, will co-ordinate the
qualification flow and the activities (evaluation of supplier's qualification plan and
Technical Report, necessity of test and reference specimen, audits in order to verify the
correct execution of the process and the application of the technical specification). At the
end of the adjustment activities and at the end of tests on the reference specimens, the
Material & Processes Unit and the Supplier Quality Unit will approve the technical Report.
All qualification documents, produced by the Supplier will be filed by Alenia Aeronautica
Procurement Quality in order to have objective evidence of the SupplierQualification and
as a reference for periodic qualification renewal.
Process Specifications Deviation

The supplier can ask for a Process Specification Deviation if it is unable to satisfy a
requirement of the process specification to apply (Process Parameter, Material, Tests,
etc.)
In order to have a specification deviation, the supplier has to use the form in attachment
10 available only for the following Alenia Aeronautica specification:
• AIT
• NTA
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The supplier has to describe in detail all the deviations for which it asks the authorization,
according to what is required by the applicable specification.
This form have to be send by the Supplier to Alenia Supplier Quality and a copy to Alenia
Purchasing Department. The Process Specification Deviation will be evaluated by Alenia
Aeronautica Processes, Materials and NDT Unit and the deviation become operative only
after a formal approval/normalization from Alenia Design Department.
In order to have an Alenia Aeronautica Customer Specification deviation, the supplier has
to ask Alenia Aeronautica Supplier Quality for the specific form. Alenia will contact the
Customer for the relevant approval after Material, Processes and NDT Unit internal
verification.
Special Process Qualification release
After the phases before described, if Alenia is the owner of the special process
specification, or if Alenia holds a Customer formal delegation, Alenia Aeronautica
Supplier Quality Unit will issue the Q.P.S. (Qualified Processes Status report) . A new
revision of the QPS will be issued for each new qualification.
If the special process specification requires Customer qualification, Alenia Aeronautica
Supplier Quality Unit will start the qualification flow, which will be completed with the
Customer acknowledgement.
Maintenance of the qualification conditions
Periodic Inspection
In order to assure ongoing quality level, appropriate periodic checks must be carried out
and documented by the Supplier, according to the applicable technical specifications.
Maintenance of plant and/or equipment

An essential element to assure the quality level of process, is that the supplier must
establish an appropriate scheduled maintenance of the plant and/or equipment used, in
accordance with its documented defined operations and expiring date that must reflect
applicable specification requirements.
Renewal of qualification
Renewal of qualification shall take place every three years, except where otherwise
stated in the applicable technical specification and/or customer requirements
specifications and, anyway, contemporary to Quality System renewal of qualification.
Supplier Quality Unit, with the co-operation of Material & Process Unit, will perform:
• audit at the Supplier to verify the process;

• repetition of the tests, when requested.
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Where the specification does not require repetition of tests, qualification may be
renewed if there is compliance with the following requirements:
• documented continuity in performance of the special process, with relevant objective

evidences;
• demonstration of ongoing adequate quality level;
• documented personnel qualification validity (at least 6 months of operative continuity
per year). Operative continuity of qualified personnel, with performance level keeping,
must be formally issued by the supplier, on an annual basis and available to Alenia
upon request.
• Approved control procedures, regarding the Special Process for inspection (NDT),
according to the last issue of applicable specification.
If the process technical specification requires the manufacturing of maintaining periodical

tests, their positive result is another requirement adding to the above.
These tests may be performed by supplier laboratory or other laboratories; anyway the
utilized laboratory shall be agreed with Alenia Aeronautica (Material, Processes and NDT
Unit and the Supplier Quality Unit). The supplier may also ask Alenia Aeronautica for the
performing of this test, forwarding a purchase order to the Commercial and Credit
Management Unit, with the indication of: applicable specification, quantity of test
specimens, kind of test to be realized.
Test specimens will be sent to the Alenia Material, Processes and NDT Unit according to
the indication of the Commercial and Credit Management Unit, which will inform Supplier
Quality System Unit.
At the end of all these activities, obtaining sufficient results, the Procurement Quality Unit
will issue updated Q.P.S. (Qualified Processes Status).
Loss of qualification
Qualification lapses in the following cases:
• when qualification is not renewed within the time limits prescribed

• when a process is suspended for more than one year, excepted where
otherwise specified in the technical specification
• significant variations in plant/equipment (displacements, modifications, major
maintenance etc.) ;
• important changes to the applicable specifications;
• serious ongoing quality level decline of the process performance.
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Suppliers subcontracting the execution of Special Processes to a Third Source
Special Processes qualification for a third source used for fabrication

It’s Alenia Aeronautica responsibility to qualify special process for NTA’s and AIT’s
specifications.
If the Supplier wants to subcontract to an other Supplier (not qualified by Alenia
Aeronautica) he can ask to Alenia Aeronautica Supplier Quality Unit and Purchasing
Department a written uthorization to qualify its own Subcontractor only if the following
condition/requirements are satisfied:
• The Supplier is qualified according NTA's/AIT's specifications to perform internally the

special process which it intends to subcontract
• The Supplier has a "specialist" for the process which it intends to subcontract, in order
to manage the qualification of its Subtier
• The Supplier has a demonstrated technical competence (the in subject process have
been qualified since 2 years without major problem)
Alenia Aeronautica may release the authorization when:
• There are no limitation fixed by Customer or Airworthiness Authority

• The Supplier has enough resources to manage by itself the qualification of its own
Subcontractors
• There are Non Destructive Testing (NDT) involved (unless the supplier has a 3rd level
professional)
If the above conditions are satisfied, Alenia will perform a Capability Assessment to the
Supplier and to its Subcontractors. When the Capability Assessment is completed with
good results, Alenia Aeronautica Procurement Quality Unit and Purchasing Department
will authorize the Supplier to qualify its Subcontractor by itself.
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The Supplier, during the qualification activity of its Subcontractors, have to satisfy the
following requirements:
• Alenia Aeronautica Supplier Quality and Purchasing Department have to be informed

by the Supplier about the qualification schedule of its own Subcontractors, in order to
allow the presence of Alenia Aeronautica S.p.A. personnel.
• Perform, in accordance with the requirements of this Operative Procedure and the
applicable specifications, all the verification of performance and conformity for the
plant (specimens analysis, audit to the Subcontractor, etc.)
• Verify training and personnel certification requirements (as prescribed by this
Operative Procedure)
• Perform a formal approval of Subcontractor Technical Report (in accordance with the
requirements of this Operative Procedure)
• Inform Alenia Aeronautica Supplier Quality about the formal qualification of the
Subcontractor.
Notes :
• The Alenia Aeronautica Supplier is responsible of the quality of the product also for
the activities performed by its Subcontractors and it will assure the specifications
updating and the technical surveillance of its Subcontractors
• The Supplier have to continue to perform internally the subcontracted process
• The qualified Subcontractor can be utilized only by the Supplier which has performed
the qualification (other Suppliers cannot utilize this subcontractor without their own
qualification)
• The Supplier will be responsible to manage the technical documentation, sending it
to its Subcontractor.
At the end of qualification process of the Subcontractor by the Supplier, Alenia

Aeronautica Supplier Quality Unit will update the Qualified Process Status (QPS) of the
Supplier adding the specification and the Subcontractor where the process is performed.
The requirements to maintain, to renew, to lose the special process qualification have to
be in accordance with the above specified requirements. The authorization to the supplier
to qualify by itself a subcontractor for a special process will decade at its expire date of
the involved special process. Alenia Aeronautica Supplier Quality will verify the correct
management and surveillance of the Supplier Subcontractors with the periodic audits to
the involved Supplier.
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Alenia Aeronautica additional requirements applicable to Class C1; C2; C3; D1; H1;
H2 Suppliers performing the industrialization of a product
Industrialization of a product performed by Alenia Aeronautica

Supplier
General
The industrialization of an aeronautical product means:
• Processing of the working and control documents

• Drawing and designing of tooling for manufacturing/assembly and inspection
• Tooling manufacturing and inspection
What is produced by the industrialization of an aeronautical product, will be approved

and/or validated by Alenia Aeronautica only after positive response of FAI activity.
• Requirements for working and inspection documents
Working and inspection documents shall comply with following requirements:
General requirements
− Documents shall have the reference number, with revision index and issue
date.
− Documents shall refer to applicable drawings with relevant configuration and
revision.
Requirements for traceability of materials, operators and inspectors
− To assure traceability, identification of materials and/or components to be

used, shall be recorded.
− Shop travelers shall record manufacturing/inspection activities in order to have on
the document the status of working phases, of traceability, of used materials, of
inspections performed complete of date and results of stamp and sign of
inspections.
− Handling, packaging and storage methods have to be indicated.
Requirements concerning production process

− Applicable process specification, included special processes, with relevant
revision index shall be indicated. It is necessary to indicate on shop travelers the
specification parameters to be used to satisfy design requirements.
− Certified personnel necessity to perform special processes shall be indicated
for each phase of shop travelers.
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Requirements concerning tooling

− P/N or the code and revision of the tooling to be used for manufacturing and
inspection phases shall be indicated.
Requirements concerning inspections

− In process and final inspection to be performed on product that needs to verify
the conformity to the applicable requirements shall be indicated. The inspection
methods shall be detailed. When is not possible to include inspection method in
the shop travelers, it is necessary to prepare specific Inspection Plan. This
Inspection Plan shall be called out in the shop travelers.
− The “required” values of inspection data with the related tolerance and the
“actual” values shall be indicated on shop travelers.
− When necessary, measurement instrument recording identification number and
calibration expiration date shall be recorded on shop travelers.
− Only for processes under statistical control, it is needed to indicate key
characteristics to be recorded and control charts have to be as reference.
− Interchangeability and/or replaceability requirements have to be indicated.
Certificate of Conformity
The Supplier shall issue a Certificate of Conformity to the requirements hold in the
Technical Specifications of the work package.
Certificate of Conformance shall refer to identification number, revision and issue date of
applicable specification.
The Certificate of Conformity signed by Supplier authorized personnel, shall be issued
with the Shop Travelers of assigned work package.
• Requirements for design of fabrication, assembling and inspection tooling to be

delivered to Alenia Aeronautica.
The drawings and design specification of the parts and of aircraft assemblies to be
produced are source data to be considered as reference to define tooling typology and
their technical/fabrication requirements.
The Alenia "Technical Specification" for fabrication and assembly tooling shall indicate
the above requirements.
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Drawings approval and issue

Supplier shall submit to Alenia Aeronautica a plan of activities of design, manufacturing
and inspection of tooling.
The plan shall include a Tooling Design Review carried out with Alenia Aeronautica
partecipation. Tooling drawings shall be submitted by the Supplier to Alenia Aeronautica
for approval.
Moreover, Supplier shall submit to Alenia Aeronautica for approval a document showing
the minimum technical characteristics, tolerances and inspection method necessary for
tooling verification (Key Points).
Tooling Inspection Plan for first acceptance and issue

Inspection Plan for tooling acceptance (assembly jigs, fabrication and inspection
tooling) define all necessary inspections to be performed to show tooling compliance
with tooling drawings.
Supplier is responsible to issue and to submit to Alenia Aeronautica for approval, the
Inspection Plan according to the schedule indicated in the Operative Quality Plan.
Tooling inspection plan shall be in accordance with technical data in approved drawings
and include all the technical characteristics that need to carry out the final inspection.
In case of fabrication tooling can be submitted to Alenia Aeronautica approval a
simplified document with the following information:
Tooling sketch with clear indication of characteristics to be checked.

Table with comparison between theoretical values and actual values, including
tolerances.
Tooling Periodical Inspection Plan approval and issue

Tooling Periodical Inspection Plan defines all inspections to be performed, with the
defined frequency to verify tooling functional and technical characteristics status.
Supplier is responsible to submit Tooling Periodical Inspection Plan to Alenia Aeronatica
for approval. Content of Tooling Periodical Inspection Plan may be part of the Tooling
Inspection Plan for first acceptance.
Tooling user manual

When required by Alenia Aeronautica, the Supplier shall provide in addition to tooling
drawings, an user manual approved by Alenia Aeronautica.
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• Requirements for tooling fabrication and inspection
Tooling approval and validation

Supplier, once completed tool fabrication, is responsible to perform tooling inspection
activities according on the Alenia Aeronautica approved “Tooling Inspection Plan".
A specific "Tooling Inspection Report" shall be issued by the Supplier after tooling
inspection. The Supplier shall deliver tooling drawings with a Certificate of Conformity
that declares with “Source Data" and applicable “Design Manual".
The Supplier shall deliver the tool with a Certificate of Conformity that declares tooling
compliance with applicable tool drawings and specification. Inspection Report and
Certificate of Conformity shall be signed by Supplier authorized personnel.
Alenia Aeronautica tooling approval, during receiving inspection or at supplier (if the
Supplier is fully responsible of the work package), is shown through a specific stamp on
the tooling. ln this way, tooling is considered compliant with applicable
drawings/specification and is ready for first article production. Alenia Aeronautica tooling
validation is possible after successful closure of the “First Article Inspection" or the
closure of the follow-up actions, and is demonstrated by a second stamp.
At this point tooling is ready for production of conform parts/assemblies.

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H2 Suppliers using CAD CAM systems
Requirements for supplier using CAD/CAM systems
Configuration Control
Supplier shall submit to audit the configuration of its hardware and software used in
CAD/CAM process, shall demonstrate and show them on Alenia Aeronautica request.
Supplier shall prepare technical procedure to assure its CAD/CAM systems, software and
data verification will be identified, checked and recorded.
In particular, for Boeing programs, the Supplier has to satisfy the synchronization
requirement for its CATIA system. This requirement is not only the verification of the
same CATIA issue between the Supplier, Alenia Aeronautica and Boeing, but also a
synchronization process verified via Boeing “project file”.
Data protection
Supplier shall establish and apply specific procedures to ensuring integrity and safety of
data supplied by Alenia and/or came out by these and also of data produced by the same
Supplier. The procedure shall include:
• Read/Write protection
• Password
• Accesses
• Files
• Back-up periodicity
• Environment controlled and relative data recorded
For classified programs, with data restricted the conditions to be applied shall be defined
with specific program rule issued by Alenia Aeronautica
Inspection, measuring and test equipment

The Supplier shall control calibrate and maintain efficient Inspection, measuring and test
equipment (e.g.: plotter, NMC for coordinates measurement).
The Supplier shall establish the extent and the frequency of checks and shall maintain
records.
Personnel Training
The Supplier shall establish and implement procedures to ensure the necessary
knowledge of the specific used CAD/CAM process. Appropriate record of personnel
training shall be filed and maintained for Alenia Aeronautica verification.
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Inspection of supplied CAD/CAM product

The supplier shall perform test, check and final inspection before Alenia Aeronautica
delivery, in compliance with operative Quality Plan, to show the conformity of all products
produced by CAD/CAM.
Data exchange
The Supplier shall show its hardware and software capability and data exchange
methodologies.
The Supplier shall establish and apply procedure for verification/acceptance of data
supplied by Alenia Aeronautica.
Non conformities management and control

The Supplier shall establish and implementing procedures to prevent unintended use and
installation of non conforming data sets, mathematics models and surfaces.
Control activity shall provide for identification, documentation, evaluation segregation
disposition of non conforming products and for notification to the functions concerned.
Testing
The supplier shall establish and implement procedure for test criteria, test plans and
related results documentation to be used for periodical verification of software, hardware,
source data and program of CAD/CAM process.
CAD/CAM inspection authority

The Supplier shall establish and implement procedures to ensure:
• validation of Master Dimension Data (MDD) each time they are extracted from a
DATASET for inspectors of parts or tooling;
• validation shall ensure correctness of extracted surface configuration and traceability
of original DATASET in Alenia Aeronautica;
• validation shall be carried out by an operator trained and qualified by Supplier and
approved by Alenia Aeronautica Signature and stamp of operator shall be collected
and filed.
The approval of Supplier personnel for “Master Dimension Data (MDD) extraction for
inspection” activity, consists of two steps:
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Phase 1 – Documentation evaluation:
this phase requires the evaluation of the following documents:

• Designed personnel Curriculum Vitae, signed by Quality Responsible of the
Supplier (minimum requirement is two years of documented experience on
CAD/CAM activity)
• Certificate, released by the training Company, related to the participation to
training courses in compliance with the following requirements in terms of contents
and duration:
“Basic Course on 3D model definition”: (20 hours)
Geometrical entity definition (curved line and elementary surfaces)
Use of CAD/CAM procedures (data extraction, plotting, etc.)
“Course on surfaces”:(8 hours)
Advanced surfaces definition
Data extraction (Master Dimension Data production, inspection grid
generation)
• Contents of training courses
• Evidence of final examination of training courses (when available)
Phase 2 – MDD Extraction for Inspection:
This phase is developed as follows:

• Supplier designed personnel performs the MDD extraction with the witness of an
Alenia Aeronautica qualified operator
• The dataset coming from MDD extraction is verified by Alenia Aeronautica against
CAD data (design authority)
The number and the type of data set to be used as test will be agreed by Alenia
Aeronautica and the Supplier.
The qualification of the Supplier for MDD Extraction for inspection will be released after
positive conclusion of the two above steps (documentation evaluation; MDD extraction
test).
The internal certification of the personnel and its periodic renewal (through a declaration
that the operator is continuously and correctly performing the activity) are Supplier
Responsibility. Evidence that this activities have to be available for Alenia Aeronautica
verification.
DATASET independence
The Supplier shall ensure the independence of flow of DATASET employed for
production from flow of DATASET employed for Quality Control and objective evidence of
file independence shall be provided.
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H2 Supplier using Coordinate Measurement Systems (CMS)
Additional requirements related to the use of Coordinate Measurement Systems

(CMS)
General
Supplier shall issue procedures that describe how assure the definition and control of
accuracy, responsibility and reproducibility of related measurement process (CMS).
CMS Systems Configuration Management Procedure

The CMS Configuration Management as Laser Tracker System and supplied dataset is
performed according to documented Procedures.
In particular every year the configuration is subject to a verification and validation by
means of an audit with the following scopes:
• Monitoring and Certification of new Hardware and Software systems

• Identifying the modifications and relevant level of approval
• Ensuring proper revision/maintenance through a specific contract with software
supplier
The original Programs (example: LEICA Programs) have to be stored in environmentally

controlled area, under the responsibility of Quality Function of the Supplier.
Alenia Aeronautica notification/approval

Software used by the Supplier CMS (example : Laser Tracker) shall be only the Alenia
Aeronautica and/or Alenia Aeronautica Customer accredited.
Whenever a change to the System Configuration is necessary for evolution, internal
investment or dismissal process, approval from Alenia Aeronautica and/or Alenia
Aeronautica S.p.A. Customer will be required prior the change being implemented.
Evidence of “Non-Affecting” changes

In case of any change in the hardware or software, whose class of modification is such to
not require approval from Alenia Aeronautica and/or Alenia Aeronautica S.p.A. Customer,
or the change doesn't affect product integrity or validity of Data representation to
Customer Programs, Supplier will provide the required evidence to the Alenia
Aeronautica and/or Alenia Aeronautica S.p.A. Customer.
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Software : Organization - Back Up – Responsibility

The top folder “Hard – Disk (C:/)“ shall be organized in two sub-folders, identified as:
• “COMP” (completes, containing only files to be stored as historical data)

• “ACTIVE” (containing all work files)
It is responsibility of Supplier Quality Control to perform the backup of data as follows:
• General Back-up (quarterly based) via “floppy disk (1,4”) or CD-ROM, labeled and
dated. Storing area: Metrological Lab (environmentally controlled area)
• File Management: to move ”files” defined “ACTIVE” to sub-folder “COMP”, when
activity is completed and non necessary files have been deleted.
“LASER TRACKER” System Management

The “Laser Tracker” is a tridimensional measurement system which aim is to obtain the
coordinates of the measured points; it is composed by:
• Laser Interferometer
• Targets (protected in suitable boxes)
• Adapters
• Weather station
All the above is integrated by a Personal Computer/Operative System under which runs a
dedicated Software. The measurement process shall be developed using a certified
reference (Scale Bar).
CMS Inspection Plans:

It shall take into account that any adapter that is not OEM supplied or purchased shall be
a Designed Adapter; if used, it shall have a released design/drawing and prior to use it
must be inspected and accepted by Supplier Quality Assurance.
Requirements for calibration
Alignment and Certification of the “Laser Tracker System”

• The Laser Tracker System will be aligned and certified approximately every six
months.
• The initial six months alignment/certification of the laser tracker system will be
performed by either the manufacturer company on-site (LEICA Geosystems) or by
other approved Agency.
• The following six months alignment/certification will be performed by LEICA
Geosystems. This alignment/certification will result in the issuance of N.I.S.T. (or
equivalent) Certification.
• If schedule, availability or other factors will not allow the laser tracker alignment and
N.I.S.T. certification by Leica Geosystems, it is acceptable to substitute laser tracker
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alignment and certification by Supplier and Alenia Quality Assurance personnel, by

Leica Geosystems (on-site) or by other approved agency.
This exception must be requested and authorized by Alenia and it can only be
authorized once in a 12-month period.
If an alignment and certification must be performed before the next scheduled six
month alignment and certification, it will be performed by either Supplier and Alenia
Aeronautica Quality Assurance personnel, Leica Geosystems (on-site) or other
approved agency.
• The Supplier Metrology Laboratory will archive all alignment data and if appropriate
issue a certification of the laser tracker system. The certification period will be 180
days.
• The Supplier Metrology Laboratory will archive all alignment data and certification
Information.
Calibration and Certification of “Scale Bars”

• Periodic Calibration and Certification of Laser Tracker Scale Bars will be performed
annually by the Supplier Metrology Laboratory or an approved outside agency.
• Laser Tracker Scale Bars shall be inspected and certified in accordance with Supplier
Operative Instructions.
• A list of all “Scale Bars” and their part/unit number is contained in Supplier Operative
Instructions.
• The Supplier Metrology Laboratory will archive all calibration data and certification
information.
Calibration and Certification of “Retroreflectors” and “Target Adapters”

• Periodic Calibration and Certification of retroreflectors and target adapters will be
performed annually by the Supplier Metrology Laboratory or an approved outside
agency.
• Target adapters and retroreflectors shall be dimensionally inspected and certified per
the Original Equipment Manufacturer (OEM) drawings or documents.
information.
Calibration and Certification of “Environmental Monitors” and pressure or temperature

sensing devices used with “Laser Tracker System”
• Periodic Calibration and Certification of environmental monitors or pressure and
temperature sensing devices used with the laser tracker system will be performed
annually by the Supplier Metrology Laboratory or an approved outside agency.
• Those monitors or devices will be calibrated and certified per the OEM drawings and
specifications.
information.
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Personnel Training
Supplier Training Program

Supplier training Quality Procedure governs the training activity (planning, training
sessions, records) for manufacturing and inspection personnel.
The following topics regard the training program for the Laser Tracker System as
referenced in applicable supplier operative instructions and include but are not limited to:
• Laser Tracker Measurement Requirements (data collection parameters, Quality

Assurance acceptance parameters)
• Hardware and software set-up
• “Retroreflector” and Two Face field checks (field calibrations)
• “Interferometer” (IFM) Index field check and alignment (field calibrations)
• “Absolute Distance Meter (ADM) Field Checks” end alignment (field calibrations)
• “Intermediate Alignment” (field calibrations)
• “Full Alignment” (field calibrations)
• Laser Tracker Measurement (stationary and sphere fit point measurement, continuous
measurement)
• Targeting (including specialized targeting (such as hidden point rods) and software
set-up requirements)
• Scaling (CTE)
• Coordinate System creation and manipulation (Scale, Axis Alignment, Best-fit and
Weighted Least Squares Transformations)
• “Data format”, control and archiving
Supplier Metrology Laboratory personnel will receive training in the interpretation of

alignment data as it pertains to the certification of “Laser Tracker” Systems.
Training Records
All training records up-date shall be maintained and be available for Alenia Aeronautica
and/or Alenia Aeronautica S.p.A. Customer review.
Records
All records associated with the measurement process by Laser Tracker System will
demonstrate compliance with applicable documents. The process will include, but is not
limited to system changes and additions / new software testing.
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The following elements will be kept and properly maintained on file according to
applicable supplier procedures:
• calibrations,
• “logs”,
• training,
• “password” allocation,
• print-out reports with acceptance/rejection.
All this records will be kept and properly maintained on file according to applicable
supplier procedures. When applicable, these records will be available to the Alenia
Aeronautica and/or Alenia Aeronautica S.p.A. Customer and traceable to specific
delivered products.
Audit
Audits will be performed, on annual basis, by Alenia Quality Supplier Organization to
verify the correct application of Internal Quality Procedures and operative instructions for
the CMS management.
Operative Instructions
As mentioned in the previous paragraphs, the Supplier shall issue operative instructions
to ensure the CMS management.
The operative instructions shall be submitted to Alenia Aeronautica and/or Alenia
Aeronautica Customer for approval.
7.1.3 Identification and traceability
Alenia Aeronautica additional requirement applicable to Class C1; C2; C3; D1; D2
Suppliers
The Quality Management System of Supplier shall ensure control of the job
cards/assembly lists before they are released to verify that they include all necessary
inspection activities.
Conformance with the specified requirements shall be assured by full, clear and
comprehensive descriptions of the test/inspection activities to be included on the work
cycles and/or assembly lists.
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For programs on which advanced statistical techniques are used, all the operations
regarding key characteristics must have special descriptions, including for example:
• Traceability and reference to the inspection cards to be used

• Traceability and identification of the measuring and test equipment and instruments
• Definition of the number of parts constituting the batches to be inspected
Parts subject to statistical control shall be suitably identified and traceable.

The quality system of supplier shall allow identification of the product to be maintained
throughout the product life.
The supplier shall maintain the traceability of the configuration of the product ready for
delivery in order to know its configuration status including any differences between the
actual status and the agreed status.
Alenia Aeronautica additional requirement applicable to Class A1 Suppliers

providing serialized equipment
Equipment label
If not otherwise specified in the equipment technical specification or in other program

procedures, the serialized equipment shall be furnished with a “equipment label”
mod. EST. 31.063 (1-91)
When required in the specification, recalled by the Contract/Purchase Order, the

supplier shall prepare the equipment Log Book.
"EQUIPMENT LABEL" shall accomplish following functions:
• To check configuration of equipment installed on aircraft

• To contribute to define the list of equipment installed on airplane
• To keep control of correct storing
• To keep storing/installation/maintenance operations traceability.
It is necessary that equipment supplier start LABEL filling according to this procedure
(see Annex 5).
Log Card for equipment
If it is required by the technical specification recalled by the Contract/Purchase

Order, the Supplier shall issue the Log Card for equipment.
The Log Card is in Annex 6 with the relative filling instructions.
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7.1.4 Customer property (No Alenia Aeronautica additional requirement)
7.1.5 Preservation of product
Alenia Aeronautica additional requirements applicable to all Suppliers
Packing, storage and delivery

The packing and identification processes must be in accordance with the specification
required by Alenia Aeronautrica.
Methods for preservation and segregation of the product must be applied if the product is
submitted to Alenia Aeronautica inspection.
Minimum documentation for the delivery of the product will have to include:
• Certificate of Conformity or JAA FORM ONE

• Minutes of the acceptance tests ( when applicable )
• Manufacturing and expire date (when applicable)
• A.I.R / A.T.R. – Assembly Inspection Report/ (if required)
• C.V.R. – Change Verification Report (according to the program specifications)
• Additional documentation concerning the equipment, as it is defined in the applicable
Quality Program Requirements, recalled by the Contract/Purchase Order.
7.2 Control of monitoring and measuring services

Applicability
International Class
Quality Standard
EN 9100 A1; B1; C1; C2; C3; H1; H2
EN 9110 F1
EN 9120 E1; E2
ISO 9001:2000 D1; D2; G1
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8 MEASUREMENT, ANALYSIS AND IMPROVEMENT
Applicability:
International Class
Quality Standard
EN 9100 A1; B1; C1; C2; C3; H1; H2
EN 9110 F1
EN 9120 E1; E2
ISO 9001:2000 D1; D2; G1;
8.1 General (No Alenia Aeronautica additional requirement)
8.2 Monitoring and Measurement (No Alenia Aeronautica additional requirement)
8.2.1 Customer satisfaction (No Alenia Aeronautica additional requirement)
8.2.2 Internal Audit
Alenia Aeronautica additional requirement applicable to all Suppliers

Personnel assigned to perform Internal Audit must be trained.
8.2.3 Monitoring and measurement of processes (No Alenia Aeronautica additional

requirement)
8.2.4 Monitoring and measurement of product
Alenia Aeronautica additional requirement applicable to Class C1; C2; C3

Suppliers using Alenia Aeronautica Suppliers having the Incoming Inspection Delegation
(IID)
Use of Alenia Aeronautica Suppliers having the Incoming

Inspection Delegation (IID)
Case 1 – Authorization by Alenia Aeronautica of the Subcontractor to use an

Alenia Aeronautica raw materials Supplier having the Incoming Inspection
Delegation (IID) issued by Alenia Aeronautica.
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If Alenia Aeronautica authorizes the Subcontractor to purchase raw materials according

to rules of the Incoming Inspection Delegation (IID), the following aspects must be
considered:
Note: The raw materials supplier shall be already authorized by Alenia Aeronautica to
operate according to IID requirements
• Purchase Orders have to indicate the amount of material and the contract clause
concerning the IID between Alenia Aeronautica and material Suppliers.
• Raw material Supplier have to provide the product applying the Delegated Quality
Control Plan (DQCP) already approved by Alenia Aeronautica.
• The Subcontractor shall be informed about raw material Supplier Customer’s
Coordinator list (with relative test marks) approved by Alenia Aeronautica.
• The Subcontractor shall be informed about technical specifications for which the IID is
released.
• The raw material Supplier must be monitored by mean of the “Quality Rating”. The
minimum value of the “Quality Rating” (already defined with Alenia Aeronautica) shall
be reached and a monitoring shall performed by the Subcontractor; data must be
submitted to the Alenia Aeronautica S.p.A. attention.
• The Subcontractor shall issue an internal procedure for the IID management and he
shall submit it to the Alenia Aeronautica for approval. A minimum content of the
procedure will be as follows:
− Responsibilities and tasks of the raw material Supplier Customer Coordinator,
− Rules for Subcontractor personnel training on IID use,
− Quality Rating requirements,
− The DQCP,
− Additional IID requirements (relationship between subcontractor and raw material
Supplier),
− Double check requests according to the content of the DQCP.
If the Subcontractor is in compliance with the previous requirements, it can be

authorized by Alenia Aeronautica to activate the IID with the raw materials
Suppliers.
Planned and/or unplanned audits will be performed by Alenia Aeronautica in order to
verify the activities concerning the previous authorization.
Case 2 – Alenia Aeronautica authorization for Subcontractor to purchase Standard

from an Alenia Aeronautica Service Provider
Operative methods foreseen by the Alenia Aeronautica document QPRA03.099 shall be

performed.
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Alenia Aeronautica additional requirement applicable to Class C1; C2; C3 Supplier

which receive from Alenia Aeronautica material pending incoming inspection
acceptance.
Material provided by Alenia Aeronautica pending incoming

inspection acceptance
If the material has been provided by Alenia Aeronautica to a Subcontractor and the
inspections and incoming tests are not completed, Alenia Aeronautica will inform the
Subcontractor with a letter.
After that, when laboratory results concerning previous tests will be available, Alenia
Aeronautica will inform the Subcontractor using a dedicated form.
If test are positive, the Subcontractor shall:
• File the shipping document;

• Certify and deliver the product (manufactured with the above material) after
including in the shipping documents information about Laboratory Test results,
reference and date of Alenia Aeronautica relevant communication.
In case of materials scraps, the Subcontractor shall:
• Identify and return back timely all material to Alenia Aeronautica U.O.S.A.
Department;
• Immediately stop manufacturing activities involving the scrap material;
• Inform Alenia Aeronautica U.O.S.A. Department about items already manufactured
connected to an Alenia Aeronautica order, this to achieve an eventual commercial
agreement.

Suppliers which the Source Inspection has requested for
Source Inspection
If Alenia Aeronautica requires the execution of the Source Inspection, product

manufactured/assembled c/o Subcontractor shall be in conformity with what required by
purchase order and by technical/qualitative applicable document.
Product conformity shall be also guaranteed during the intermediate phases of

construction/assembling, when some parts or product working cannot be verified at the
end of operation.
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The final product acceptance is exclusive competence of Quality Control of Alenia

Aeronautica Operative Unit which receive it at its Plant. This involves that positive result
of source inspection at Supplier facility is not binding for its final acceptance.
Supplier tasks
At the end of productive activities and once prepared the certification and delivery
documents, the Supplier shall formally (through fax) communicate to
− Quality Control of Alenia Aeronautica involved Operative Unit, and for knowledge a
− Alenia Aeronautica Procurement Unit, for knowledge
that the supply (P/N - Program) is available c/o their productive plants for Alenia
Aeronautica to be submitted to inspection.
Before starting inspection, the Supplier shall prepare the following documents for Alenia
Aeronautica inspector:
• purchase order;
• applicable drawing;
• instructions and applicable specifications indicated by drawings;
• applicable technical/qualitative document;
• manufacturing and Assembling Job Cards;
• Assembly Inspection Report (where applicable);
• Test report (where applicable);
• certification documents;
• transfer list
Verification of product delivery documents

After the inspection, the Alenia Aeronautica inspector shall verify the certification and
delivery documents.
Inspection formalization
After carried out as in the previous points, the inspector issues the "Source Inspection
Form" to certify product inspection.
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8.2.4.1 Inspection documentation
Alenia Aeronautica additional requirement applicable to all Suppliers (Class G1

excepted)
Certification document provided by Supplier
Certificate of Conformity
General
When product/service realization is completed, the Supplier shall formally declare to
Alenia Aeronautica the compliance of the product/service to the contract/Purchase Order
(including requirements of the applicable technical/quality documentation). The action is
formalized through a Certification of Conformity.
The Supplier is responsible for the Certification of Conformity of product/service to
specification/contract requirements. For this reason, the Supplier shall formally declare in
Quality Plan the authorized personnel to release Certification of Conformity.
The supply acceptance could be suspended in case of missing certification
document attached to the delivered product.
This Certification has to be filled carefully, for correctness, completeness and clearness
about the reported data.
The supply acceptance could be suspended if the certification documents are
wrongly filled.
Supplier shall institute, keep up-to-date and make available to Alenia Aeronautica a
register where is clear the link between certification of conformity and supply.
Suppliers can use its form but the following requirements have to be satisfied:
Certificate of Conformity (C.d.C) contents

The C.d.C shall report at least the following information:
• Identificative supplier logo

• Alenia Aeronautica Operative Unit where the supply have to be delivered
• Certificate number
• Contract number and/or Alenia Aeronautica Purchase Order
• Variant number of Alenia Aeronautica Purchase Order (if applicable)
• Program cost code
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• Progressive number of supply components starting from 01, listing:

− P/N and revision index (where applicable);
− Description;
− Delivered quantity;
− Reference to technical/qualitative document supplied by Alenia Aeronautica
with relevant revision level (where applicable);
− Last completed operation of the shop travelers (if applicable).
• Lot number, serial number, effectivity (where applicable)
• Number Supplier shipping document
• C.d.C. Issue date
• Supplier authorized person signature
• First name and last name of supplier authorized person
• Declaration of conformity to the technical/qualitative document supplied by Alenia
Aeronautica at the last applicable issue
Note: In case that technical/qualitative document supplied by Alenia Aeronautica is an off

load shop traveler, a copy of the document (only stamped) shall be enclosed to C. of C..
C.of C. issue
C.of C. shall be issued in three copies so divided:
• The original enclosed to shipping document;

• A copy, when applicable, in the product packing;
• A copy filed by supplier.
Alenia Aeronautica additional requirement applicable to Suppliers issuing JAA

FORM ONE
Certificate of approval JAA FORM ONE issue
Certificate of Approval – JAA FORM ONE
The issue of this certification is possible only if Supplier has an approval according to
EASA IR Part 21 Sub. G Production Organization Approval (P.O.A.), and in the
Authorized Operation List (L.O.A.) includes product supplied to Alenia Aeronautica.
This is possible when exists a specific commercial agreement between Alenia
Aeronautica and Supplier, and a specific procedure agreed with Airworthness Authority.
When the above requirements are satisfied a JAA FORM ONE shall be issued by
Supplier Certifying Staff, in accordance with Production Organization Exposition
(P.O.E.), and the supplier Quality Plan, approved by Alenia Aeronautica.
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If the Supplier is certified according to ENAC Technical regulation, the Supplier issues
JAA FORM ONE under the above conditions and according to the delegation received by
the Authority.

Suppliers in case of deviations of the product to be delivered.
“Transfer List” preparation

Transfer List
If product to be delivered to Alenia Aeronautica have some deviations from the required
configuration, the Supplier prepares the Transfer List (Annex 4) to be enclosed to the
Certificate of Conformity.
All the deviations from Alenia Aeronautica required configuration, must be listed in the
Transfer List before the supply delivery and formally authorized (by fax, letter) by Alenia
Aeronautica. Reference of Alenia Aeronautica authorization must be indicated in the
Trasfer List. Transfer list and every document that the list requires (non conformity,
modification, authorization, etc) with inspection stamp is part of Certification of Conformity
and it is to be attached with list.
8.2.4.2 First Article Inspection (F.A.I.)
Alenia Aeronautica additional requirement applicable to Class C1; C2; C3 Suppliers
First Article Inspection – F.A.I.
General
At the beginning of serial production, the Supplier must qualify the production process
performing the F.A.I. which has to be submitted to Alenia Aeronautica approval. Alenia
Aeronautica shall be preliminary informed by the Supplier about the execution of a F.A.I.
in order allow its participation.
The F.A.I. allows to verify adequacy of tooling, shop travelers and product inspection
method. F.A.I. shall be performed and/or repeated in the same operative conditions of
serial production; this in order to verify the conformity to the applicable technical quality
documentation.
F.A. I. is a fundamental test to be performed during development and set up of the
manufacturing process to assure its repetitivity according to drawings/specifications.
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Necessity of F.A.I.
F.A. I. is required in the following cases:
• Production of a new part number and/or part assembly.
• Use of new tools/methods for the manufacturing of the part.
• P/N modification concerning Fit, Form and Function.
• Start-up of production activities after an interruption of more than two years or in
compliance with specific program requirements.
• Products with high defect rate, when corrective actions were performed with no
positive results.
• Change in manufacturing process.
• External event having influence on manufacturing process.
Necessity of “partial” F.A.I.

In case of production process and/or applicable technical documentation change, a
"limited" first article inspection shall be performed (only on the characteristics involved by
the change).
"Limited F.A. I. activity" is foreseen in the following cases :
• Minor product configuration change

• Special tooling modification.
• Change of manufacturing/speciaI tooling location
• Findings arisen during previous performed first article inspection.
• Change in the “condition of supply” document.
• Material change.
• Part Programs modification for Numerical Control machines.
NOTE: Prototypes and parts manufactured with processes different from the ones
applied in standard manufacturing can not be considered as substitution of F.A.I.
FAI forms and execution

F.A.I. activity must be performed according to the International Standard EN 9102 using
Forms enclosed to the above standard. Alenia Aeronautica requires more data regarding
tooling and job card verification: for this reason a Form 2 different shall be used with two
attachments in addition to the EN 9102 “Form 2”.
This modified Forms are in Annex 11 of this External Operative Procedure.
Different additional requirements, if any, will be reported in the Program Quality
Requirements.
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Approval
F.A.I. activities have to be approved by Alenia Aeronautica Quality Control of the
Operative Unit responsible for the off-load and by customer/Airworthiness authority
according specific program requirements.
Supplier responsibility
Through its own Quality Control, the Supplier:
• Plan F.A.I. activities. This planning must be sent to Alenia Aeronautica Supplier
Quality Control of the Operative Unit responsible for the off-load;
• Performs F.A. I. and submits to Alenia Aeronautica for approval;
• Sends F.A. I. Report to Alenia Aeronautica with shipment documents;
• Files F.A.I. report and retains the document for ten years (if a different retain period
may be required by specific program requirement).
• Sends to Alenia Aeronautica Quality Control of the Operative Unit responsible for the
off-load, with a frequency stated by program requirement, F.A.I. status for each
program.
Main points to be checked during F.A.I. activities:
a) Check of drawing characteristics

The checks of the all characteristics called by drawings must be recorded (see Form 3 of
EN 9102).
In particular, verification of interchangeability and functional requirements through
analysis of reports (if applicable) and/or installation tests, if any, shall be done.
Characteristics which are not accessible must be checked at appropriate stage and not
modified by subsequent operations.
b) Compliance to Technical Requirements

Appropriate material source identification (lot number provided by Alenia Aeronautica or
by material manufacturer) and material/part conformity evidence, released by qualified
source, shall be provided.
All the applicable drawings, processes/material specifications or other technical
documentation on the shop travelers shall be at the last applicable issue.
The applicable special processes (if any) shall be pointed out on the shop travelers with
detailed instruction on measurable characteristics; special processes shall be followed by
a control phase on the shop travelers. Evidence of special processes qualification shall
be provided.
Evidence of operators certification to perform specific activities shall be provided.
Instruments used for characteristics verification must be traceable. A verification that
inspection instruments are adequate shall be performed.
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c) Production process repetitivity

Shop travelers shall indicate the involved parts identification and shall be approved by
Quality Control.
All shop travelers shall be duly filled in each section; all necessary manufacturing
activities and controls shall be checked out by stamps and performed operation date
shall be recorded to ensure continued product conformance.
The indication “FAI REQUESTED” shall be called on the shop travelers.
Verification that all F.A.I.’s of parts/subassy have been performed and approved by
Alenia Aeronautica, before start of F.A.I. on an assy, shall be done. F.A.I. activities shall
be correctly documented, including all necessary information, and appropriately stored.
All tooling used for production activity and/or parts acceptance shall be indicated on the
shop travelers with their identification code and applicable revision; tooling capability to
produce and/or inspect the product for the drawing requirements shall be verified and
documented during the F.A.I., before their final release to production.
Production tools and gauges shall be checked to verify their correct use and inspection
status in particular: identification, certification/calibration, instructions for use shall be
verified.
Calibration and status of instruments, equipment indicated in the shop travellers and
used during production/control process, shall be verified. The instruments/equipment not
controlled by Metrological Laboratory utilized.
A functionality check for production machines utilized during the process, and in
particular for precision machines (e.g. boring machine) whose performance highly affects
product quality, shall be done by the Function responsible of their management.
Moreover, special attention shall be given to the verification of some machine
characteristics such us precision, wear, use suitability.
Note: Record of all F.A.I. discrepancies and/or non conformities shall be maintained to
permit cause evaluation and corrective actions implementation by the responsible
personnel. In any case discrepancies and non conformities shall not permit F.A.I.
approval; at least all verification where non conformities or discrepancies have been
pointed out shall be repeated. Corrective Actions application, significant manufacturing or
processes change shall imply F.A.I. total or partial repetition. Part manufactured with
different methods from the standard ones shall not be used for F.A.I.
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Alenia Aeronautica additional requirement to Class A1 Suppliers
First Article Configuration Inspection (F.A.C.I.)
Definition
The F.A.C.I. of an equipment consists in his functional and physical examination in
addition of the verification of its compliance to the configuration defined by the applicable
specifications and drawings before the delivery to Alenia Aeronautica.
Procedure for FACI execution

Every new equipment (new P/N) must be subjected to FACI, except written exclusion in
Alenia Aeronautica Technical/Quality documentation, which is applicable to a specific
equipment.
For the execution of the FACI., the Supplier will execute the verification requested in the
form in attachment 10 and relative instructions for filling in.
Necessity of FACI repetition

The FACI must be repeated in the following cases:
• Equipment modification.
• Start-up of equipment production after a production suspension as required in
program reels.
• Moving / modification of the production line
8.2.5 Evidence of non-conformities – Certificate of Conformity
Alenia Aeronautica additional requirement applicable to Class E1; E2 Suppliers
Certificate of Conformity from the original manufacturer

When the Supplier carries out the Stockiest/Distributor or Broker activity, it must ensure
the traceability of original manufacturer’s certificate.
The Supplier shall
• issue its own Certificate of Conformity according to the Alenia Aeronautica additional
requirement applicable to all Suppliers.
• enclose the original manufacturer’s Certificate of Conformity end Test Report (when
required) according to Alenia Aeronautica purchase document (Purchase
order/Contract) through the specific quality requirements for the in subject supply.
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8.3 Control of non-conforming product
Alenia Aeronautica additional requirement applicable to all Suppliers (except Class

G1)
Notification to Alenia Aeronautica of suspected or verified non-

conformities for product delivered by Suppliers - “Alert”
General
When the Supplier is sure or suspects that on product, already delivered to Alenia
Aeronautica there are non conformities not detected, it must immediately provide a
communication to Alenia according to the following modalities.
The Supplier has to issue a proper internal procedure according to this External
Operative Procedure, in order to identify the responsibilities and the internal operative
modalities.
Preliminary notification of the defect

As soon as the Supplier is sure or suspects that on product, already delivered to Alenia
Aeronautica, are present non conformities not detected, it must send a preliminary
informative report, within 12 hours from the discovering or the arising of a suspect. This
in order to allow Alenia Aeronautica to identify all suspected parts and to start the proper
actions.
This report must be sent utilizing the first part of the "ALERT" form (Attach. 9), signed by
the Supplier Quality Control Chief and addressed to the following Alenia Departments:
− Procurements,
− UOSA (for the sub-contracting activities),
− Quality Control of Alenia Aeronautica Plant which receive the parts.
This preliminary informative report must contain the following items:
• Identification Number and date of the report

• P/N and Name
• Quantity
• S/N (if applicable)
• Batch number
• Program (if applicable)
• Alenia purchase order
• Delivery date to Alenia
• Number of transport document
• Alenia Plant where products are consigned
• Number of the C. of C. issued for Alenia
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• Detailed description of the defect which could be on supplied products (eventually use
sketch and attachment).
• Quality Control Chief’s signature and date
• Alert identification number
The numbering of the "Alert" form shall be executed by the Supplier.

Every issued "Alert" must be reported on a proper register which reports, at least, the
following items:
• "Alert" number and date

• P/N of the involved parts
• Denomination
• Quantity
• Detected defect description
Completing of Alert form

After the preliminary notification, the Supplier shall complete the investigations
considered necessary on parts not yet shipped, segregate them and start all the action to
put under control the non conformities. After the investigation and the above actions on
all defected parts at its site, the Supplier shall provide, within 3 working days, the
information about the detected defect, completing the 2nd part of the "Alert" form, signed
by the Quality Control Chief.
The Supplier will provide the following information which can be reported on attached
paper (identified) and called out in the relative Box of the "Alert" form.:
• Actions made on parts which show the defect

• Possible non conformities tags issued
• Description of the non conformity cause
• Description of the corrective actions which are undertaken in order to correct the
cause of the non conformity
• Possible instruction and/or advises
• Effectivity of the corrective actions (attach the possible implementation plan, including
the effectiveness verification)
• Signature of the Quality Control Chief and date.
The Supplier will, however, supply every information in order to particularly clarify the
discovered defect, with the relative documentation enclosed.
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Suppliers
Non conforming material management for outside production

activity
Non conforming Management document issuing (MRR or RdC)

When non conformity occurs, the supplier (by means of its Quality Unit) shall formalize
the non conformity by issuing the non conformity tag (MRR or RdC).
Non conformity tag form Numbering

It must be indicated:
• the Product/Project/Service (P/N, description, quantity, etc)

• all activities requested by contract/Purchase order.
Alenia Aeronautica Quality Control identifies for each Supplier and for each program, a
numerical range to be used for the document code identification. This code will be used
by Alenia Aeronautica data base system for traceability, monitoring and statistical
analysis. The supplier must assure the chronological sequence within the its numerical
range (related to specific program).
Material Segregation
The supplier must identify non conforming materials by means of labels or tags. These
labels or tags have to indicate MRR code number. The MRR number must be indicated
on the working document in order to point out the stand-by condition.
The supplier must segregate non conforming materials in order to avoid its non
authorized use.
Non Conformity Management
• Non conformity management with a technical disposition requiring activity at

Supplier
Non conforming management following steps:
− Non conformity identification, MRR/ RdC Form filling-up and its shipping to Alenia
Aeronautica.
− Application and inspection of technical disposition received by Alenia Aeronautica.
− MRR / RdC filing.
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• Non conformity Management with a technical disposition requiring activity

during the next assembly phases
The technical disposition, in order to solve the non conformity, can foresee activity during
the next assembly phases. These could be performed by an Operative Unit different from
the one which generated the non conformity in the first place.
The steps to be followed for the management of non-conformity document issued by a

Supplier with a technical disposition which requires an assembly activity at an Alenia
Aeronautica Operative Unit are:
− Non conformity finding, MRR / RdC form filling-up sending to Alenia Aeronautica.
− Application and inspection of technical disposition provided by Alenia Aeronautica.
− MRR / RdC deliver to Alenia Aeronautica Quality Control Unit which performs the
tecnical disposition ctivity during assembling phase.
− MRR filing as supporting Alenia Aeronautica/Alenia Aeronautica S.p.A. Customer
approval.
In the same way, methods for the management of non-conformity document issued by a
Supplier with a technical disposition that requires activity during assembling phases at a
different Supplier must be agreed with Alenia Aeronautica
The whole management of MRR / RdC document is always under responsibility of
Supplier Quality Control which has issued the non conformity form and that it is
responsible for its filing.
Visibility status of non conformity at supplier

Supplier must provide a dedicated visibility, on a monthly basis, ordered by programs of
issued MRR / RdC for each program.
Filing time
The supplier shall file the original copy of issued non conformity documents for 10 years.
After expiration of this period, supplier shall require Alenia Aeronautica authorization to
destroy the documents.
MRR/RdC Document Filling-Up

Supplier shall manage non conformity document by means of original form. After non
conformity closure, the Supplier shall:
• file and save the MRR document
• send a copy of MRR document to Alenia Aeronautica Quality Control which receives
the parts
In some particular cases (urgency, too much distance of the Supplier, etc.), MRR
document can be sent by fax., upon authorization.
In this case the supplier shall attach the faxed copy to the original document.
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Basic Rules
Parts having different P/N shall not be treated by the same document.
Parts having same P/N, but affected by different types of defects shall not be treated by
the same document.
Non conformity description shall be in Italian and when required in English, too.
Non conformity shall be clearly indicated by detailed description of defect by significant
dimensional checks and completed by a sketch or partial drawing copy.
Dimension reported on the MRR/RdC document shall be in the same units user in the
drawing.
Instructions for MRR form compilation by the supplier

The instructions for the compilation of MRR/RdC form blocks, which are Supplier
responsibility, are in annex 8.
Re-classification of the non-conformity

If non conformity is classified as concession (Concession/Waiver/Raporte de Controle) by
the Alenia Aeronautica Design Office, Supplier upon Alenia Aeronautica Quality Control,
shall change the non conformance document according to the specific program
requirement.
8.4 Data analysis (No Alenia Aeronautica additional requirement)
8.5 Improvement
8.5.1 Continuous improvement (No Alenia Aeronautica additional requirement)
8.5.2 Corrective actions (No Alenia Aeronautica additional requirement)
8.5.3 Preventive actions (No Alenia Aeronautica additional requirement)

IAY G05 C Part 2

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Coding Date

IAY G 05 C March 2004

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Delivery of the Assembly Inspection Report

Alenia Aeronautica Additional Requirements applicable to Class F1 Suppliers

Maintenance of aircraft components according to JAR 145 c/o

7.1.1.1 Production documentation (No Alenia Aeronautica additional requirement)

7.1.1.2 Control of production process changes (No Alenia Aeronautica additional

7.1.1.3 Control of production equipment, tools and Numerical Control

Alenia Aeronautica additional requirements applicable to Class C1; C2; C3

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Tooling management c/o Suppliers

• Master (Mock-up that defines geometry lines and interchangeability/interface

Suppliers activities for tooling management depend from inspections to be performed, in

Periodical Inspection (Scheduled)

Any production and means of compliance tool, used to control dimensional

• Periodic Inspection Plan preparing

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• Periodic Inspection Plan

− Type of inspection to be performed

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• Definition of kind and frequency of Inspection

− Project of the tool audits function

In any case tools will be submitted to C-type inspection at least a year.

• Inspection plan approval

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• Inspection state by mean of marking of the tool

− Certification of inspection plan with date and stamp

• Tolerances on periodic inspection expiry date

− To allow the finishing of an assy already in working

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Non recurrent inspection

• Modification of tool design

If it is not differently agreed with Alenia Aeronautica, execution of this activities is

7.1.1.4 Control of work transferred, on a temporary basis, outside the

7.1.1.5 Control of service operations (No Alenia Aeronautica additional requirement)

7.1.2 Validation of processes for production and service provision

Alenia Aeronautica additional requirements applicable to Class C1; C2; C3 Suppliers

Special processes qualification and qualification renewal

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This activities require personnel training, qualification and certification.

If Alenia Aeronautica is the owner of the special process specification and/or if

Alenia Aeronautica, through the O.P.S.P. (Outside Droduction Specification Plan),

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The main elements of the qualification process are the following:

A special process may require the qualification:

NDT Procedure Approval

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• Name of NDT III Level accepted by Alenia Aeronautica

Process Specifications Deviation

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Special Process Qualification release

Maintenance of the qualification conditions

Maintenance of plant and/or equipment

• audit at the Supplier to verify the process;

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• documented continuity in performance of the special process, with relevant objective

If the process technical specification requires the manufacturing of maintaining periodical

• when qualification is not renewed within the time limits prescribed

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Alenia Aeronautica additional requirements applicable to Class C1; C2; C3

Special Processes qualification for a third source used for fabrication

• The Supplier is qualified according NTA's/AIT's specifications to perform internally the