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    AEROSPACEAEROSPACE

    QUALITY MANAGEMENTQUALITY MANAGEMENT

    SYSTEMSYSTEM -- 91009100Dale K. GordonDale K. Gordon

    RollsRolls--Royce North AmericaRoyce North AmericaPast ChairmanPast Chairman

    Americas Aerospace Quality GroupAmericas Aerospace Quality Group

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    Aerospace Quality StandardsAerospace Quality Standards

    Numbering SystemNumbering System

    International StandardsInternational Standards -- 91xx91xx

    Are planned for harmonization across all 3 aerospaceAre planned for harmonization across all 3 aerospace

    sectors and are recognized globallysectors and are recognized globally

    Americas StandardsAmericas Standards -- 90xx90xx

    Are published for use by AAQG, may become anAre published for use by AAQG, may become an

    91XX standard at a later date91XX standard at a later date

    ASAS StandardsStandards --AmericasAmericas

    Published by Society of Automotive EngineersPublished by Society of Automotive Engineers ENEN StandardsStandards -- EuropeEurope

    published in Europe by AECMApublished in Europe by AECMA

    JIS QJIS Qoror SJACSJAC is the Japan / Asia Equivalentis the Japan / Asia Equivalent

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    Aerospace Quality SystemAerospace Quality System

    StandardsStandards

    INTERNATIONAL STANDARDSINTERNATIONAL STANDARDS 91009100 -- Quality System for AerospaceQuality System for Aerospace

    ManufacturersManufacturers 91019101 -- ChecksheetChecksheet for 9100for 9100

    91029102 -- First Article InspectionFirst Article Inspection

    91039103 -- Management of Key CharacteristicsManagement of Key Characteristics

    91109110 -- Quality System for Aerospace RepairQuality System for Aerospace RepairStationsStations

    91119111 -- ChecksheetChecksheet for 9110for 9110

    91209120 -- Quality System forQuality System for PassPass--ThroughThroughDistributorsDistributors

    91219121 -- ChecksheetChecksheet for 9120for 9120

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    Tier 4Tier 4-- Make to Print / Machine Shops/Make to Print / Machine Shops/

    ProcessorsProcessors

    Tier 2Tier 2

    Integrators /Integrators /

    Source Control/Source Control/

    Software Dev./Software Dev./

    Major AssembliesMajor Assemblies

    Tier 5Tier 5-- Distributors (Fasteners, Raw Materials,Distributors (Fasteners, Raw Materials,

    Commodities, Adhesives, Special Materials)Commodities, Adhesives, Special Materials)

    Tier 3Tier 3-- Integrators /Integrators /

    Source Control / SpecialtySource Control / Specialty

    Electronics / Wiring / CompntsElectronics / Wiring / Compnts

    Tier 6Tier 6-- Raw Materials (Castings, Forgings, Sheet, etc)Raw Materials (Castings, Forgings, Sheet, etc)

    Aerospace Supply ChainAerospace Supply Chain

    Tier 1Tier 1

    SpecialP

    rocess

    es

    SpecialP

    rocess

    es

    Comp

    anySpe

    cific

    Comp

    anySpe

    cific

    orNA

    DCAP

    orNA

    DCAP

    91009100

    91209120

    90039003

    Tier 1Tier 1

    Vehicle / Airframe /Vehicle / Airframe /

    Propulsion ManufacturePropulsion Manufacture VariationReduction

    VariationReduction

    910291029103

    9103

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    ISO TC20ISO TC20 -- WG11WG11

    ISO Technical Committee 20ISO Technical Committee 20 --Aircraft & Space VehiclesAircraft & Space Vehicles

    Established Working Group 11 (April 1997)Established Working Group 11 (April 1997)

    Chartered to develop and publish an internationalChartered to develop and publish an international

    quality system standard based upon ISO 9001 forquality system standard based upon ISO 9001 for

    the aerospace industrythe aerospace industry United States (Gene Barker) ConvenerUnited States (Gene Barker) Convener

    Members:Members:

    BrazilBrazil ChinaChina FranceFrance

    GermanyGermany JapanJapan MexicoMexico

    United KingdomUnited Kingdom United StatesUnited States

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    ISO TC 20

    WG11

    AS9100 EN 9100

    AS9000 prEN 9000-1

    Americas

    StandardEuropean

    StandardISO 90011994

    World Aerospace Quali ty

    Standard ; AS/EN/JI S Q 9100

    International Quality SystemInternational Quality System

    Standard Creation 1998Standard Creation 1998

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    Aerospace Quality SystemAerospace Quality System

    ModelModel

    C

    o

    m

    pa

    n

    y

    R

    e

    q

    mn

    t

    s

    AS/EN/JIS Q

    9100

    Intl

    Reqmnts

    &Company

    Reqmnts

    Internationally Agreed Implementation Processes

    Risk

    Mgnt

    Prgrm

    Mgnt

    Special

    Process

    Process

    Rqmts

    Deliver

    able

    Non-

    Deliver

    MRO

    9110

    Dist.

    9120

    Service

    Specific

    Requirements

    Quality System Requirements - International

    Standard ISO 9001

    Common Aerospace Quality System Requirements -

    International Requirements 9100Program

    Specific

    Requirements

    Hardware

    Specific

    Requirements

    Software

    Specific

    Requirements

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    Why 9100?Why 9100?

    To standardize Aerospace qualityTo standardize Aerospace quality

    expectations on aexpectations on a globalglobal levellevel

    To achieve improvements in quality andTo achieve improvements in quality andreducereduce costscosts throughout the value streamthroughout the value stream

    ISO 9000 model for quality does notISO 9000 model for quality does notcapturecapture regulatory requirements orregulatory requirements or

    importance of safety, reliability orimportance of safety, reliability or

    maintainabilitymaintainability Captures aerospaceCaptures aerospace supplementssupplements agreedagreed

    to at an international levelto at an international level

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    ISO9001 versus AS9100ISO9001 versus AS9100

    AS 9100 version is formatted to match ISO 9001:2000 andAS 9100 version is formatted to match ISO 9001:2000 and

    added requirements that provide foradded requirements that provide for --

    Regulatory organizations interfacesRegulatory organizations interfaces Configuration ManagementConfiguration Management

    Design and Development V& V., & V&V testingDesign and Development V& V., & V&V testing

    Control of changes in Production ProcessControl of changes in Production Process

    Control of production equipment, tools, NC machinesControl of production equipment, tools, NC machines

    Control of work in outside facilitiesControl of work in outside facilities

    Control of service operationsControl of service operations

    First Article InspectionFirst Article Inspection Inspection documentationInspection documentation

    These added requirements enables a standardizedThese added requirements enables a standardized

    approach to supplier flow down requirementsapproach to supplier flow down requirements

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    Year 2000 ISO 9000 RevisionsYear 2000 ISO 9000 Revisions

    A moving target . . .

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    ISO 9001:2000 / 9100:2001ISO 9001:2000 / 9100:2001

    TimelineTimeline

    DEC. 2003

    ISO 9001:1994

    2000 2001 2002 2003

    ISO 9001:2000

    9100 : 1999 9100 : 2001

    9100A:2001 includes both ISO 9001:1994 and

    ISO 9001:2000 models until December 2003

    9100:2003 ?

    Note: AS9000 / AS9100 section 2 phase out December 15, 2003

    Certificates are expected to expire in line with ISO 9001 requirements

    Does NOT mean that approvals are invalid

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    FAA Endorsement ofFAA Endorsement of

    AS9100:2001AS9100:2001

    The Aircraft Certification Service still believes that the effecThe Aircraft Certification Service still believes that the effectivetive

    implementation of AS9100implementation of AS9100 -- Rev A will continue to enhance anRev A will continue to enhance an

    organizationorganizations overall performance. The statement found ins overall performance. The statement found in

    Section 1.1 General: statesSection 1.1 General: states It is emphasized that the qualityIt is emphasized that the quality

    management system requirements specified in the standard aremanagement system requirements specified in the standard arecomplementary (not alternative) to the contractual and applicablcomplementary (not alternative) to the contractual and applicablee

    law and regulatory requirements.law and regulatory requirements. is still a requirement that mustis still a requirement that must

    be adhered to.be adhered to.

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    Current USACurrent USA DoDDoD PositionPosition

    Proposed Department of Defense (Proposed Department of Defense (DoDDoD) Adoption of the) Adoption of the

    AS9100:2001 Quality Management SystemsAS9100:2001 Quality Management Systems --AerospaceAerospace --

    Requirements (Nov. 2001)Requirements (Nov. 2001)

    prepared ...prepared ... DoDDoD adoption notice for the AS 9100:2001 toadoption notice for the AS 9100:2001 to

    provide information for document visibility and facilitateprovide information for document visibility and facilitate

    document availability todocument availability to DoDDoD personnel.personnel.

    International Aerospace Quality Standard AS 9100, 2001 edition,International Aerospace Quality Standard AS 9100, 2001 edition,Qual i ty Management SystemsQual i ty Management Systems----Aerospace Requ irements,Aerospace Requirements, waswas

    adopted on March 1, 2002 for use by the Department of Defenseadopted on March 1, 2002 for use by the Department of Defense

    ((DoDDoD). The standard specifies additional requirements). The standard specifies additional requirements

    identified by the aerospace industry specifically for anidentified by the aerospace industry specifically for anaerospace quality management system based on ISOaerospace quality management system based on ISO

    9001:20009001:2000 Qual i ty Management Sys tems Requ irementsQual i ty Management Sys tems Requ irements..

    C t NASA P itiC t NASA P iti

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    Current NASA PositionCurrent NASA Position

    on 9100on 9100

    NASA issued Adoption notice on April 8thNASA issued Adoption notice on April 8th2002, signed by Dr. Michael Greenfield,2002, signed by Dr. Michael Greenfield,

    Associate Administrator for Mission andAssociate Administrator for Mission and

    Safety Assurance.Safety Assurance.

    This notice makes AS9100A available forThis notice makes AS9100A available for

    use by NASA for procurements for alluse by NASA for procurements for all

    programs.programs.

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    SPACE CONSIDERATIONSSPACE CONSIDERATIONS

    ISO TC20 / SC14 and IAQG haveISO TC20 / SC14 and IAQG have

    onon--going project to supplementgoing project to supplement

    9100 w/ special considerations for9100 w/ special considerations forSpace needsSpace needs

    Includes Risk Management & Safety and MissionIncludes Risk Management & Safety and Mission

    Assurance emphasisAssurance emphasis Use as supplement to 9100Use as supplement to 9100

    Consideration for full inclusion at next revision ofConsideration for full inclusion at next revision of

    91009100 Other industries / applications are considering usingOther industries / applications are considering using

    91009100 -- Weapon systems and Nuclear energy industryWeapon systems and Nuclear energy industry

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    91009100 ChecklistChecklist -- 91019101

    IAQG developed 9101 Common Checklist toIAQG developed 9101 Common Checklist to

    be used by industry to cover all ISO 9001 &be used by industry to cover all ISO 9001 &

    9100 elements9100 elements -- allows industry to shareallows industry to share

    audit informationaudit information

    Must be used by Certification Bodies whenMust be used by Certification Bodies whenperforming 9100 auditsperforming 9100 audits

    Scoring feature is currentlyScoring feature is currently

    used by many organizationsused by many organizations

    91109110 R i St ti Q litR i St ti Q lit

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    91109110 Repair Station QualityRepair Station Quality

    SystemSystem

    Status of 9110Status of 9110

    New version was developed with ManufacturersNew version was developed with Manufacturers--MRO,MRO,

    DoD, FAA and Airline inputsDoD, FAA and Airline inputs

    Takes latest version of FAA Part 145 into accountTakes latest version of FAA Part 145 into account

    Will replace EN 9110 in Europe that is already in useWill replace EN 9110 in Europe that is already in use

    since 1999since 1999

    3 Airlines and most European Manufacturers3 Airlines and most European Manufacturers

    already use it to specify requirements to MROalready use it to specify requirements to MRO

    supplierssuppliers

    Registration / Certification

    plans being put in place

    91109110 R i St ti Q litR i St ti Q lit

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    91109110 Repair Station QualityRepair Station Quality

    SystemSystem

    Why 9110?Why 9110?

    Manufacturers want a Quality System flowManufacturers want a Quality System flow--downdown

    requirement for their repair activityrequirement for their repair activity Manufacturers want reputable suppliers that haveManufacturers want reputable suppliers that have

    repair station approvals and a defined qualityrepair station approvals and a defined quality

    systemsystem There is a need to put all of the expectations inThere is a need to put all of the expectations in

    one document for Repair and Maintenanceone document for Repair and Maintenance

    organizationsorganizations Military is very interested in having defined QualityMilitary is very interested in having defined Quality

    System requirements for MROSystem requirements for MRO

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    91209120 Distributor Quality SystemDistributor Quality System

    EN 9120 developed and implemented inEN 9120 developed and implemented in

    Europe forEurope for pass throughpass through stockistsstockists //

    distributors that handle parts and supplies thatdistributors that handle parts and supplies thatare used in aerospace productsare used in aerospace products

    Checklist 9121 is also availableChecklist 9121 is also available

    Based on 9100, but only appliesBased on 9100, but only applies

    necessary system requirementsnecessary system requirements.. 9120 is available9120 is available

    Registration plan to be available 1/2003Registration plan to be available 1/2003

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    SECTOR / IAQG PROJECTSSECTOR / IAQG PROJECTS

    Projects are Designed to reduceProjects are Designed to reducerequirements variationrequirements variation

    Projects are designed to provideProjects are designed to providesupport and compliance enhancementsupport and compliance enhancement

    to areas that Aerospace has identifiedto areas that Aerospace has identifiedfor Risk Reduction (resource limitation)for Risk Reduction (resource limitation)

    Projects are designed to increaseProjects are designed to increase

    process capabilitiesprocess capabilities Projects are designed to improveProjects are designed to improve

    products or processesproducts or processes

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    Aerospace Quality StandardsAerospace Quality Standards (cont.)(cont.)

    International StandardsInternational Standards

    First Article Inspection (9102)First Article Inspection (9102)

    Management of KeyManagement of Key

    Characteristics (9103)Characteristics (9103)

    Record Retention (9130)Record Retention (9130)

    NonconformanceNonconformanceDocumentation (9131)Documentation (9131)

    2D Bar Coding (9132)2D Bar Coding (9132)

    Part Qualification ProcessPart Qualification Process(9133)(9133)

    Other ProjectsOther Projects

    Less thanLess than 9100 (AS9003)9100 (AS9003) Operator Self VerificationOperator Self Verification

    (ARP)(ARP)

    Deliverable Software QualityDeliverable Software Quality NonNon--Deliverable SoftwareDeliverable Software

    Direct Shipments (ARP 9004)Direct Shipments (ARP 9004)

    Sampling PlansSampling Plans 3D Digital Data Storage (ARP)3D Digital Data Storage (ARP)

    Contract Clauses (ARP)Contract Clauses (ARP)

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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 QualityMajor 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 IndustryThere are significant benefits to the Aerospace Industry

    !! Working to develop our International processes toWorking to develop our International processes to

    incorporate the new approachincorporate the new approach

    !! International approach is based on a single agreedInternational approach is based on a single agreedstandard,standard, harmonizationharmonization of system application and sharedof system application and shared

    informationinformation

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    Industry Acceptance / UsageIndustry Acceptance / Usage

    The IAQG implementation metrics show that;The IAQG implementation metrics show that;

    75+% of members have implemented 9100 internally and75+% of members have implemented 9100 internally and

    to their suppliersto their suppliers 25+% of members have implemented 9102, FAI, internally25+% of members have implemented 9102, FAI, internally

    and to their suppliers.and to their suppliers.

    10% of companies have implemented the recently10% of companies have implemented the recently

    published 9103, Component Proving, internally and to theirpublished 9103, Component Proving, internally and to their

    suppliers.suppliers.

    Implementation is gaining momentum and this willImplementation is gaining momentum and this will

    increase, particularly when the new Boeing Qualityincrease, particularly when the new Boeing Quality

    System is reissued.System is reissued.

    The sector implementation approaches are also makingThe sector implementation approaches are also making

    good progress but the benefits from global mutualgood progress but the benefits from global mutual

    recognition of Quality System audits is still not quiterecognition of Quality System audits is still not quite

    there yetthere yet -- working the global database.working the global database.

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    QUESTIONSQUESTIONS