aerospace quality management - industry approach mark p. allen chairman americas aerospace quality...
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AEROSPACE QUALITY AEROSPACE QUALITY MANAGEMENT - INDUSTRY MANAGEMENT - INDUSTRY APPROACHAPPROACH
Mark P. AllenMark P. Allen
ChairmanChairmanAmericas Aerospace Quality GroupAmericas Aerospace Quality Group
SAE Aerospace Committee G-14SAE Aerospace Committee G-14February 14th 2002February 14th 2002
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AAQG LegitimacyAAQG Legitimacy
• Committee of the Society of Automotive Engineers - Committee of the Society of Automotive Engineers - designated Committee G14. designated Committee G14.
• Operations are under the guidance and rules of SAE Operations are under the guidance and rules of SAE committees. committees.
• A cooperative organization within the aerospace A cooperative organization within the aerospace industry in the Americas (including North, Central and industry in the Americas (including North, Central and South Americas). South Americas).
• Processes are established in a set of agreed, Processes are established in a set of agreed, documented, operational procedures. documented, operational procedures.
• Not a legal entity. It is the responsibility of individual Not a legal entity. It is the responsibility of individual companies to implement such agreed upon common companies to implement such agreed upon common procedures.procedures.
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AAQG PurposeAAQG Purpose
Establish and maintain a dynamic cooperation based on trust between Americas Establish and maintain a dynamic cooperation based on trust between Americas aerospace companies on initiatives to make significant improvements in quality aerospace companies on initiatives to make significant improvements in quality performance and reductions in cost throughout the value stream.performance and reductions in cost throughout the value stream.
Initial focus is to continuously improve the processes used by the supply chain Initial focus is to continuously improve the processes used by the supply chain to deliver consistently high quality products, thereby reducing non - value to deliver consistently high quality products, thereby reducing non - value added activities and costs. added activities and costs.
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AAQG and IAQG ObjectivesAAQG and IAQG Objectives
Establish commonality of quality standards and Establish commonality of quality standards and requirementsrequirements– Common aerospace basic quality systemsCommon aerospace basic quality systems– Best practices in aerospace industryBest practices in aerospace industry– Performance metricsPerformance metrics
Establish process of continuous improvement at suppliersEstablish process of continuous improvement at suppliers– Industry expectationsIndustry expectations– Lean manufacturingLean manufacturing– Supplier performance metricsSupplier performance metrics
Establish methods to share resultsEstablish methods to share results– AuditsAudits– InspectionsInspections– Supplier performanceSupplier performance
Establish implementation plans that bring the initiative to lifeEstablish implementation plans that bring the initiative to life– Obtain regulatory concurrenceObtain regulatory concurrence
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AAQG 2002 GoalsAAQG 2002 Goals
Document policies and proceduresDocument policies and procedures
Formalize a charterFormalize a charter
Initiate migration from system compliance to Initiate migration from system compliance to product conformanceproduct conformance
More closely align with industry associations & More closely align with industry associations & other groups to eliminate redundant activitiesother groups to eliminate redundant activities
DoD, Space, AIA…..DoD, Space, AIA…..
Continue project initiations and completionsContinue project initiations and completions
Continuing education for the membershipContinuing education for the membership
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AAQG - MembershipAAQG - Membership Members
Goodrich Boeing Company* Bombardier - Canada* Embraer Aircraft - Brazil* ENAER - Chile GE Aircraft Engines* Gulfstream Aerospace Honeywell* HELIBRAS - Brazil Lockheed Martin*
LMAASA - Argentina Northrop Grumman* Parker Aerospace
Rockwell-Collins Rolls-Royce Corp. Raytheon Aircraft Textron*
Bell Helicopter Cessna Aircraft
United Technologies* Pratt & Whitney Sikorsky Aircraft Hamilton Sundstrand
Vought Aircraft
Non-Voting Members Suppliers RAB IAAR
* Denotes - IAQG Council Member
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AS 9100 Industry Acceptance AS 9100 Industry Acceptance / Usage/ Usage
The IAQG implementation metrics show that;The IAQG implementation metrics show that; 46% of members have implemented 9100 internally and 46% of members have implemented 9100 internally and
to their suppliersto their suppliers 18% of members have implemented 9102, FAI, 18% of members have implemented 9102, FAI,
internally and to their suppliers.internally and to their suppliers. 8% of companies have implemented the recently 8% of companies have implemented the recently
published 9103, Component Proving, internally and to published 9103, Component Proving, internally and to their suppliers. their suppliers.
– Implementation is gaining momentum and this will Implementation is gaining momentum and this will increase, particularly when the new Boeing Quality increase, particularly when the new Boeing Quality System is reissued.System is reissued.
– The sector implementation approaches are also The sector implementation approaches are also making good progress but the benefits from global making good progress but the benefits from global mutual recognition of Quality System audits is still mutual recognition of Quality System audits is still not quite there yet - not quite there yet - we need the global database.we need the global database.
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9100 Standard Alignment 9100 Standard Alignment with ISO 9001:2000with ISO 9001:2000
IAQG had the responsibilityIAQG had the responsibility
Aligned aerospace requirements with the new ISO 9001:2000Aligned aerospace requirements with the new ISO 9001:2000
Incorporated lessons learned - clarified requirementsIncorporated lessons learned - clarified requirements
Coordination and resolution was by geographic sectorsCoordination and resolution was by geographic sectors
Americas (AAQG)Americas (AAQG) Europe (EAQG)Europe (EAQG) Asia (SJAC)Asia (SJAC)
Goal to publish revision to AS9100 and prEN9100 and any other Goal to publish revision to AS9100 and prEN9100 and any other
translated versions - est. June 2001translated versions - est. June 2001
AS9100A published by SAE in August 2001AS9100A published by SAE in August 2001
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9100:2001 Highlights9100:2001 Highlights
Tokyo, March 2000Tokyo, March 2000
– 1st Draft - Provided to IAQG Sectors for review1st Draft - Provided to IAQG Sectors for review
Seattle, June 2000 Seattle, June 2000
– Consolidation of Sector commentsConsolidation of Sector comments
September, 2000 September, 2000 - Draft updated to 9001 FDIS- Draft updated to 9001 FDIS
Toulouse, November 2000 Toulouse, November 2000
– Continued review and consideration of changes for clarification & Continued review and consideration of changes for clarification & “lessons learned” “lessons learned”
January, 2001 January, 2001 - Draft updated to final ISO 9001:2000- Draft updated to final ISO 9001:2000
New Orleans, March 2001New Orleans, March 2001
– Final Review and approvalFinal Review and approval
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9100:2001 Highlights 9100:2001 Highlights (cont.)(cont.)
Intent of aerospace-unique requirements are not changed Intent of aerospace-unique requirements are not changed in new version of 9100in new version of 9100
– ISO 9001:2000 revision now has requirementsISO 9001:2000 revision now has requirementsdesired by industry, eliminating somedesired by industry, eliminating somerequirements from 9100:1999 versionrequirements from 9100:1999 version
– Some requirements from ISO 9001:1994 are desired by Some requirements from ISO 9001:1994 are desired by industry and were added back to 9100:2001 versionindustry and were added back to 9100:2001 version
– 9100:2001 contains 80 aerospace unique requirements 9100:2001 contains 80 aerospace unique requirements and 18 amplifications/notesand 18 amplifications/notes
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ISO 9001:2000 / 9100:2001ISO 9001:2000 / 9100:2001TimelineTimeline
DEC. 2003
ISO 9001:1994
2000 2001 2002 2003
ISO 9001:2000
9100 : 1999 9100A : 2001
9100A:2001 will include both ISO 9001:1994 and ISO 9001:2000 models until December 2003
9100B ?
Aerospace-Sector Standard Aerospace-Sector Standard Development TimelineDevelopment Timeline
August 2001
1995 1996 1997 1998 1999 2000 2001
T/C 20WG 11
IAQG
Munich
WG 11 Review Review Formed AS9000 prEN9000-1
JointUS/Euro
EN9000-1
AS9000
Initial ARD9000 AS9000Meeting Issued Released
Start prEN9000-1
Philadelphia
Paris
prEN9100
AS9100
Madrid
Tok
yoS
eattl
eT
oulo
use
New
Orle
ans
AS9100A
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Other Party SurveillanceOther Party Surveillance(Americas Companies)(Americas Companies)
– AAQG is implementing SAE AIR 5359A documentAAQG is implementing SAE AIR 5359A document
– AIR 5359A is approved & publishedAIR 5359A is approved & published
– AAQG is working directly with Accreditation AAQG is working directly with Accreditation
Bodies to approve CB’s and AuditorsBodies to approve CB’s and Auditors
– 22 CB’s & 110+ auditors submitted by RAB have 22 CB’s & 110+ auditors submitted by RAB have
been Accredited to AS9000been Accredited to AS9000
– 22 CB’s (and 126 auditors) are Accredited to 22 CB’s (and 126 auditors) are Accredited to
AS9100 at this time. More are expectedAS9100 at this time. More are expected
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THE AMERICAS Other Party System
Registrar Accreditation Bureau
StandardsCouncil ofCanada
INMETRO
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Oversight SummaryOversight Summary
Industry Co-operation on Quality System RequirementsIndustry Co-operation on Quality System Requirements
A single global 9100 Aerospace standard A single global 9100 Aerospace standard
An agreed International process for procedure creationAn agreed International process for procedure creation
Sector processes for 2nd or Other party approvalsSector processes for 2nd or Other party approvals
Individual sector plans launched / global plans in workIndividual sector plans launched / global plans in work
Implementation planned progressively during 2001-2002Implementation planned progressively during 2001-2002
Establish a mechanism for data exchangeEstablish a mechanism for data exchange
International auditor training and qualificationsInternational auditor training and qualifications
Communication to Authorities and StakeholdersCommunication to Authorities and Stakeholders
Industry will Monitor results and maintain momentumIndustry will Monitor results and maintain momentum
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Aerospace Quality System Aerospace Quality System StandardsStandards
INTERNATIONAL STANDARDSINTERNATIONAL STANDARDS
– 9100 - Quality System for Aerospace 9100 - Quality System for Aerospace ManufacturersManufacturers
– 9110 - Quality System for Aerospace Maintenance 9110 - Quality System for Aerospace Maintenance Organizations - Organizations - In workIn work
– 9120 - Quality System for Aerospace Distributors - 9120 - Quality System for Aerospace Distributors - In workIn work
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Aerospace Quality Standards Aerospace Quality Standards (cont.)(cont.)
InternationalInternational
First Article InspectionFirst Article Inspection Management of Key Management of Key
CharacteristicsCharacteristics Record RetentionRecord Retention Nonconformance Nonconformance
DocumentationDocumentation 2D Bar Coding (Draft)2D Bar Coding (Draft) Part Qualification ProcessPart Qualification Process
AmericasAmericas
AS9003 - “Less than” 9100AS9003 - “Less than” 9100 Production Process Planning Production Process Planning
Verification (software)Verification (software) Software Quality (Embedded / Software Quality (Embedded /
Product Acceptance)Product Acceptance) Internal Auditing RequirementsInternal Auditing Requirements Sub-tier Supplier ControlSub-tier Supplier Control Direct Shipments & Electronic Direct Shipments & Electronic
SignaturesSignatures
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Industry Leaders are ListeningIndustry Leaders are Listening
Agreed to improve the overall approach to qualityAgreed to improve the overall approach to quality
Major Aerospace Companies have agreed upon Quality Major Aerospace Companies have agreed upon Quality Management System approval approachesManagement System approval approaches
A key objective is to reduce the number of auditsA key objective is to reduce the number of audits
There are significant benefits to the Aerospace There are significant benefits to the Aerospace IndustryIndustry
Working to develop our International processes to Working to develop our International processes to incorporate the new approach incorporate the new approach
International approach is based on a single agreed International approach is based on a single agreed standard, standard, harmonizationharmonization of system application and of system application and shared informationshared information
COPIES OF STANDARDS, REPORTS COPIES OF STANDARDS, REPORTS AND CHECKLISTS ARE AVAILABLE AND CHECKLISTS ARE AVAILABLE FROM SAEFROM SAE
WWW.SAE.ORGWWW.SAE.ORGSociety of Automotive EngineersSociety of Automotive Engineers
400 Commonwealth Drive400 Commonwealth Drive
Warrendale, PA 15096-0001Warrendale, PA 15096-0001
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Aerospace Quality Coordination Aerospace Quality Coordination EffortEffort
Creation of Separate “SPACE, CIVIL & DEFENSE COMMITTEES” Creation of Separate “SPACE, CIVIL & DEFENSE COMMITTEES” under AIA (incl. all associations) under AIA (incl. all associations) – Would meet to address unique needs of each industry Would meet to address unique needs of each industry
segment within the framework of a coordinated Industry segment within the framework of a coordinated Industry process. Would include participation of all affected Industry process. Would include participation of all affected Industry organizations including FAA, DoD and NASA.organizations including FAA, DoD and NASA.
AAQG process would remain unchangedAAQG process would remain unchanged– AIA Committees would join with the AAQG to integrate AIA Committees would join with the AAQG to integrate
strategy and develop the products and tools needed for strategy and develop the products and tools needed for implementationimplementation
– AAQG responsible for common standards, tools and AAQG responsible for common standards, tools and methods with supplementation for specific sector needsmethods with supplementation for specific sector needs
Involve NADCAP Activities with AAQGInvolve NADCAP Activities with AAQG– Special Process issues would be assigned to NADCAP and Special Process issues would be assigned to NADCAP and
Quality Systems would be handled through the AAQGQuality Systems would be handled through the AAQG
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AIA-SMCAQWG
NADCAP
Civil Aviation Quality
Committee
DefenseQuality
Committee
SPACEQuality
CommitteeNASA
AIAA
FAA
NDIA /EIA
DoD
CIV
IL A
VIA
TIO
NM
ILIT
AR
YS
PA
CE
Suppliers
TACTICAL
Arrangement of Quality Arrangement of Quality CommitteesCommittees
OEM’s /
PAHs
ASA /ARSA
AIA / GAMA
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SINGLE VOICE FOR QUALITY IN SINGLE VOICE FOR QUALITY IN AEROSPACE INDUSTRYAEROSPACE INDUSTRY
Proposal would Eliminate overlap in Committees and Proposal would Eliminate overlap in Committees and OrganizationsOrganizations– Reduction in resources and travel costs for participantsReduction in resources and travel costs for participants– Eliminate redundant activitiesEliminate redundant activities
Increase in Communications between Groups and LeadershipIncrease in Communications between Groups and Leadership– Focus customer and user information in many areasFocus customer and user information in many areas– Increase response and decision time for implementationIncrease response and decision time for implementation– Obtain broader involvement of suppliers, customers and Obtain broader involvement of suppliers, customers and
regulatorsregulators– Better coordination / implementation of government / industry Better coordination / implementation of government / industry
initiativesinitiatives
Provide inputs and coordination for Global Quality Issues for the Provide inputs and coordination for Global Quality Issues for the International Aerospace Quality GroupInternational Aerospace Quality Group
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ORGANIZATIONAL BENEFITS TO ORGANIZATIONAL BENEFITS TO INDUSTRYINDUSTRY Executive Quality GroupExecutive Quality Group
– Clear senior level direction with supporting resourcesClear senior level direction with supporting resources
– Ability to challenge the status quoAbility to challenge the status quo
– Includes representation from Industry AssociationsIncludes representation from Industry Associations Americas Aerospace Quality GroupAmericas Aerospace Quality Group
– Development of industry-wide (global) processes when Development of industry-wide (global) processes when appropriateappropriate
– Linkage with international organizations and initiatives Linkage with international organizations and initiatives through the IAQGthrough the IAQG
– Official alignment with an ANSI recognized Standards Official alignment with an ANSI recognized Standards Development Organization (SAE)Development Organization (SAE)
– Commitment to use products both internally and with Commitment to use products both internally and with supplierssuppliers
– Formal linkage to the supplier communityFormal linkage to the supplier community
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ORGANIZATIONAL BENEFITS TO ORGANIZATIONAL BENEFITS TO INDUSTRYINDUSTRY
AIA managed business-line unique Committees (Civil, AIA managed business-line unique Committees (Civil, Defense and Space)Defense and Space)– Involvement of all stakeholders - customers, suppliers Involvement of all stakeholders - customers, suppliers
and associationsand associations– "Authorized" linkage to political and "Authorized" linkage to political and
government/regulatory organizationsgovernment/regulatory organizations– Communication with a business-line and across parallel Communication with a business-line and across parallel
business-linesbusiness-lines– Linkage to other AIA Councils and Industry Linkage to other AIA Councils and Industry
AssociationsAssociations
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EXECUTIVE QUALITY GROUP
AM
ER
ICA
S A
ER
OS
PA
CE
QU
AL
ITY
GR
OU
PNADCAP CIVIL AVIATION DEFENSESPACE
AAQG would perform Integration AAQG would perform Integration Function (incl International)Function (incl International)
Working
Teams
Working
Teams
Working
Teams
Working
Teams
STRATEGY&
RESOURCESVALIDATION
INDUSTRY QUALITY POSITIONS / ACTIONS
STANDARDS
COMMUNICATIONS
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Proposal for New Aerospace Proposal for New Aerospace Quality Coordination EffortQuality Coordination Effort
Monday Tuesday Wednesday Thursday
Series of Structured Meetings in the Washington D.C. Area Twice a Year
CIVILAVIATION
DEFENSE
SPACE
Working
Teams
Working
Teams
Working
Teams
Working
Teams
AM
ER
ICA
S A
ER
OS
PA
CE
QU
AL
ITY
GR
OU
P
NADCAPEXECUTIVE
BOARDMEETING
EXECUTIVE QUALITYGROUP
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AerospaceAAQG Commercial Space DoD
Council Chairs Mark Allen Andy Brindisi ? ?
Standards (PT-S) Dennis Lemon x x x
Tools & Techniques (PT-T) Julie Sandrers x x x
Implementation (PT-I) D. Buehler x x x
Communications (PT-C) C. Adkisson x x x
Industry Segment Councils
Industry Industry Segment Segment
TeamsTeams
Aerospace Aerospace Project Project TeamsTeams
Leadership team includes:AAQG & Industry Segment ChairsVice-Chair - Colin ClarkeSecretary - Carolyn AdkissonTresurer - Gretchen BrothersSAE - Jay Myers, Gretchen BrothersProject Managers
AAQG Management ApproachAAQG Management Approach
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Next MeetingsNext Meetings
June 3-5, Boston, MAJune 3-5, Boston, MA
Sept. 9-11, Washington, DCSept. 9-11, Washington, DC
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QUESTIONSQUESTIONS
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Back-upBack-up
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The International Aerospace The International Aerospace Quality GroupQuality Group
IAQG
IAQG Council
IAQG General Assembly
Meetings
JAQG
SJAC
AAQG
SAE
EAQG
AECMA
National Trade
Associations
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IAQG MembersIAQG Members
•Europe• Airbus• EADS - Airbus/BDLI• Rolls-Royce and SBAC• EADS (France)• ALENIA and AIAD• SNECMA• EADS - CASA and
ATECMA• BAE Systems• Agusta• Aermacchi• Eurocopter• Dassault• Intertechnique/GIFAS• MTU Aero engine• AECMA• Volvo-Aero
•Americas• The Boeing Company• GE Aircraft Engines• Pratt & Whitney/UTC• Rockwell Collins• Honeywell• Northrop Grumman• Cessna - Textron• Rolls-Royce Corp.• Gulfstream• Embraer• BF Goodrich• Bombardier• Bell Helicopter
Textron• Lockheed Martin• Raytheon• Vought Aircraft
• Hispano-Suiza• Turbomecca• Messier-Bugatti• Thompson-CSF Sextant
•Asia• Ishikawajima Harima Heavy
Industries• Mitsubishi Heavy Industries• Kawasaki Heavy Industries• Fuji Heavy Industries• Shin Mayawa Industries• Aviation Industries of China• Korea Aerospace Industries
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Aerospace Quality StandardsAerospace Quality StandardsNumbering SystemNumbering System
International Standards - 91xxInternational Standards - 91xx– Are planned for harmonization across all 3 Are planned for harmonization across all 3
aerospace sectors and are recognized globallyaerospace sectors and are recognized globally
Americas Standards - 90xxAmericas Standards - 90xx– Are published for use by AAQG, may become an Are published for use by AAQG, may become an
91XX standard at a later date91XX standard at a later date
““AS” Standards - AmericasAS” Standards - Americas– Published by Society of Automotive EngineersPublished by Society of Automotive Engineers
““EN” Standards - EuropeEN” Standards - Europe– published in Europe by AECMApublished in Europe by AECMA
““JIS Q” is the Japan / Asia EquivalentJIS Q” is the Japan / Asia Equivalent
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Governance DocumentsGovernance Documents
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CharterCharter 100100ProcedureProcedure
EstablishmentEstablishment
102102CommitteeCommittee
MembershipMembership
103103Maintenance Maintenance of Standardsof Standards
104104CommitteeCommitteeMeetingsMeetings
SAESAEOperating Operating
GuideGuide
SAESAETech Stds BoardTech Stds Board
GovernanceGovernance
101101Project Project InitiationInitiation