sabre briefing pack: method verification approval (fixed

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SABRe Briefing Pack:Method Verification Approval (Fixed Process Document - RRES 90000)

1 | Proprietary Information | ©2019 Rolls-Royce

| Not subject to Export Control| Not subject to Export Control

The aim of this pack is to guide Suppliers through the requirements for change process applicable to RRES 90000 controlled product and covers:

• What is method change management

• Steps of the process

• Roles and accountabilities

• Taking a change from initiation to implementation

• Further material and information

Introduction

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Manage Production Method / Fixed Process:

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• It is a process by which all changes to a production method are managed with the appropriate governance to ensure our products operate equivalently in service after the introduction of change.The process is traceable in case a change is subsequently found to be detrimental

• Once products are introduced there can be a number of factors which drive the need for changing the production method

• Managing such changes is therefore key to ensure our products still meet the customer requirements without impact to safety

• Management of change ensures that all changes are introduced in a controlled and traceable manner

• The biggest risk is uncontrolled change

What is the management of method change?




4

Rolls-Royce requires Suppliers to manage a change to a production method through their Quality Management System.

When a Product Definition instructs ‘Fixed Process Control’ to RRES 90000 (Engineering Control of Manufacturing Source & Method), a Supplier must obtain approval of the Fixed Process Document (FPD). This is achieved by the submission of a Manufacturing Verification Approval (MVA) Form to Rolls-Royce. (SABRe Edition 3 - 8.5.3.1)

Applicability

A new FPD or a change to a FPD that requires ‘Engineering Control’ (EC) approval in accordance with RRES 90000.

Note:When the change is to a production source, SABRe Edition 3 8.4.2.1. shall be applied in addition to 8.5.1.3.



RRES 90000

Not Applicable

RRES 90000

Applicable

Engineering Control

NOT Required

RRES 90000

Applicable

Engineering Control

Required

External Supply

Chain

Supplier to complete Section A of the

Method Verification Approval form and

submit to Rolls-Royce.

Supplier to manage a change to a Production

Method / Fixed Process Document in accordance

with their Quality Management System.

What is the management of method change?


Process flow showing the 4 key steps from initiation to completion of a Method Verification Approval

The 4 key steps are:

Step 1 - Propose change.

Step 2 - Agree and plan tasks.

Step 3 - Execute plan.

Step 4 - Sentence change.

5



Process Work Flow – External Supply Chain


6

Method Verification Approval Form:

Section A Section CSection B

The Method Verification Approval Form is the Formal record of management of method change

The document is used to Formally record and grant Rolls-Royce engineering approval of a Fixed Process Document (FPD) in accordance with RRES 90000

Supplier Input Rolls-Royce input

Manage Production Method / Fixed Process:Process Overview


8. Sentencing of Limitation Follow-Up:

3. Sentencing Technical Verification Tasks:

PRODUCT CONTROL Authority

Signature: Date:

MANUFACTURING Engineering Authority

10. Revision Level:

12. Sentencing Business Implementation Tasks:

ENGINEERING CONTROL Authority



13. Approval Authority Name: Signature: Date:

Continuation sheet used:

Name:

6. Method / Fixed Process Identifier: 7. Revision Level:

11. Approval Authority

9. Method / Fixed Process Identifier:




4. Limitation:



Method Verification Approval 1. MVA Reference (RR) MMcs@3456

Section C - Sentencing of Tasks and Closure 2. MVA Reference (Supplier)

Approved for Implementation. Approved for Limited Implementation.

Approved. Approved with Limitation. Rejected.

Rejected

Approved. Rejected.

a. 0

b. 0

c. 0

d. 0

e. 0

f. 0

g. 0

Required level

of Control:

The proposed method adversely affects the ability of production inspection

identifying non-conformance?

The proposed method requires approval from a 3rd Party?

Implementation of the proposed method will affect continuity of supply?

The proposed method will have a negative affect on cost?

The proposed method adversely affects HSE e.g. REACH?

21. Date:20. Sponsored By Name (R-R MEA or MEP):


Continuation sheet used: 13. Define the proposed production method (include details of specific operation changes) :


16. Submission Date:15. Benefit Category:

The proposed method affects a Key Product Characteristic?

The proposed method is a new Fix Process Document (FPD), or content of an

FPD designated Engineering Control (EC) is affected (RRES 90000/92000)?

19. Preliminary Risk Assessment:

7. Project:

18. Identify previous submissions to this or a similar part / repair and SUBSTANTIATION to support the proposed change:

17. Target Completion Date:

Note: Use the Continuation sheet when MVA is for more than one Part Number.

14. Describe the business and technical BENEFIT for implementation of the proposed change:

8. RR Plant / Supplier Name

From:

To:

CONTENT OF THIS DOCUM ENT RELATING TO THE PRODUCT OR TECHNOLOGY ASSOCIATED WITH M ANUFACTURE OF THE PRODUCT, M AY BE SUBJECT TO EXPORT

CONTROL. PRIOR TO EXPORT OF THIS DOCUM ENT, GUIDANCE M AY BE REQUIRED FROM AN EXPORT CONTROL POINT OF CONTACT.

4. Part Name: 5. Method/Fixed Process Identifier: 6.Revision:3. Part Number:

Method Verification Approval

Section A - Proposal, Benefit and Preliminary Risk Assessment

MMcs@34561. MVA Reference (RR)

2. MVA Reference (Supplier)

9. Plant / Supplier Code 10. Contact Name 11. Contact Phone No. 12. Contact Email

Quality Cost Delivery HSE

New Production Method / Fixed Process Document. Change to Production Method / Fixed Process Document.


WHAT:• Step 1 consists of defining the change opportunity (From / To / Why) and completing a

preliminary risk assessment

WHO:• Change Initiator i.e. Supplier representative

HOW:

• By completing Method Verification Approval Form Section A

INPUT:• Requirement to verify a new or changed Fixed Process Document

• The 1st tier Supplier is responsible for the submission of Method Verification Approval requests, inclusive of any applicable changes by their sub-tier Suppliers

• The Method Verification Approval initial submission shall include the following:

a. The proposed Fixed Process Document in accordance with RRES 90000 Section 5.1. A draft version of the Fixed Process Document is acceptable for initial submission

b. Supporting substantiation data (if applicable)

OUTPUT:• Method Verification Approval Form Section A (completed)

7 | Proprietary Information | ©2019 Rolls-Royce

Manage Production Method / Fixed Process:Step 1 - Propose Change(MVA Section A)


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Header information

Manufacturer

Change Proposal details

Benefit of change

Similar changes /verification

Risk assessment and control

Completed by:1st Tier Supplier

Verified by:Rolls-Royce

Control level & sponsor


Manage Production Method / Fixed Process:Step 1 - Propose Change

MVA Form Section AData cells with a red triangle in the top right hand corner contain guidance on completing the cells.

a. 0

b. 0

c. 0

d. 0

e. 0

f. 0

g. 0

Required level

of Control:
















7. Project:






From:

To:












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Define the proposed change:• Detail changes to sequence of operations,

machining / special process techniques and parameters

• Reference supporting documentation relevant to the change being proposed.

• For stock materials (e.g. forging stock, casting stock, powder, bar, plate) state the current and proposed Forms

• Declare that parts of the Fixed Process that are not cited will not change.

• Does the change impact key operations in your PFMEA/Control plan

Describe the benefit:

• Define the reason for the change in terms of technical or business benefit

• State any problems that exist with the capability of the existing process or that no problems exist.

• A clear statement of the benefit to Rolls-Royce.

Identify previous submissions:

• Identify and include any previous submissions of a similar change and supporting verification evidence

Preliminary risk assessment:

• All questions require a response

• For question “d” the Supplier to consult with the Rolls-Royce contact when required



MVA Form Section AData cells with a red triangle in the top right hand corner contain guidance on completing the cells.

a. 0

b. 0

c. 0

d. 0

e. 0

f. 0

g. 0

Required level

of Control:
















7. Project:






From:

To:












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What is the significance of the questions?• They are used to identify the level of authority required to control the proposed

change and highlight the key risk that will need to be mitigated based on the level

of risk

MVA Form Section APreliminary Risk Assessment

FPD not required or EC content of an FPD not affected.

Yes - New Fixed Process Document

Yes - EC content affected, verification evidence available.

Yes - EC content affected, verification to be defined.

A Key Product Characteristic not affected.

Yes - A Key Product Characteristic affected.

Production inspection ability not adversely affected.

Yes - Production inspection ability adversely affected.

3rd Party approval not required.

Yes - Approval by a 3rd Party required.

Continuity of supply not affected.

Yes - Disruption to supply within the Plant / Cell.

Yes - Disruption to supply affecting Customer.

Cost not negatively affected, or affect agreed.

Yes - Negative affect on Plant operating cost.

Yes - Negative affect on the 'unit cost'.

HSE not adversely affected.

Yes - HSE adversely affected, but mitigation agreed.

Yes - HSE adversely affected, mitigation to be agreed.

19. Preliminary Risk Assessment

e.

f.

g.





a. The proposed method is a new Fix Process Document (FPD), or content of an FPD designated

Engineering Control (EC) is affected (RRES 90000/92000)?

b.

c. The proposed method adversely affects the ability of production inspection identifying non-

conformance?

d.


a. M

b. L

c. L

d. H

e. L

f. L

g. L

Required level of Control: Product Control Authority

The proposed method adversely affects the ability of production inspection identifying

non-conformance?





Yes - Approval by a 3rd Party required.

Continuity of supply not affected.

Cost not negatively affected, or affect agreed.

HSE not adversely affected.

A Key Product Characteristic not affected.

Production inspection ability not adversely affected.


Yes - New Fixed Process DocumentThe proposed method is a new Fix Process Document (FPD), or content of an FPD

designated Engineering Control (EC) is affected (RRES 90000/92000)?

1 9. Preliminary Risk Assessment




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1 ofContinuation sheet

Method Change Request

Continuation Sheet

When using this continuation sheet, ensure text is aligned to the applicable Section.

1.R-R Document Reference: 2.Rev:

• There are 5 ‘Continuation Sheets’ contained in the MVA template

• Use a ‘Continuation Sheet’ as appropriate, clearly identifying which Section of the Form and Data cell number the comments are aligned to e.g. Section A 7

MVA Form Continuation Sheets




WHAT:

• Step 2 consists of detailed risk assessment and definition of technical verification and business implementation tasks

• Plan development and approval

WHO:

• Manufacturing Engineer Purchase (Interface with Supplier)

• Product Control Authority

• Engineering Control Authority

HOW:

• By completing Method Verification Approval Form Section B

INPUT:

• Method Verification Approval Form (Section A completed)

• Technical verification and business implementation tasks (Proposed)

OUTPUT:

• Method Verification Approval Form (Section B completed)

• Technical verification and business implementation tasks agreed

• Implementation Plan agreed by Rolls-Royce when applicable but controlled by the Supplier

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Manage Production Method / Fixed Process:Step 2 - Agree and Plan Tasks (MVA Section B)



13

Technical Risk Assessment and Technical Verification Tasks.In this Section the technical verification tasks identified by Rolls-Royce and enacted by the Supplier.

Business Risk Assessment and Business Implementation Tasks. This will be business implementation tasks to be enacted by Rolls-Royce, but recognised by the Supplier.

Business decision to go ahead / not go ahead with the proposed plan and approval signatures.

Identification of potential stakeholders to assist in defining verification and implementation tasks.

Identifies if FAI report is required in accordance with FAI rules.

Section B is completed by Rolls-Royce


Manage Production Method / Fixed Process:Step 2 - Agree and Plan Tasks

MVA Form Section BData cells with a red triangle in the top right hand corner contain guidance on completing the cells.

a.

b.

c.

d.

e.

f.

g.

Section B - Detailed Risk Assessment, Tasks and Plan

1. MVA Reference (RR)



Verification results to be submitted to Engineering Control Authority for assessment.

5. FAI Report:

Potential Stakeholders which can help populate Section B

8. Business decision to enact the Plan: 9. Comment:



Signature:

7. Business Implementation Tasks:

Name:10. Approval Authority:




6. Business Risk Assessment: Continuation sheet used:


3. Technical Risk Assessment:

Date:

4. Technical Verification Tasks:

Approved. Rejected. Deferred.

FAIR not required. Full FAIR required. Partial FAIR required.


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Verification results to be submitted to Engineering Control Authority for assessment.

Potential Stakeholders which can help populate Section B

8. Business decision to enact the Plan: 9. Comment:



Signature: Date:Name:10. Approval Authority:


Approved. Rejected. Deferred.

• The Rolls-Royce business area shall decide if the change shall progress to the implementation phase

• The basis for the change request approval will consider the total cost of acquisition to Rolls-Royce. The justification defined in Section A of the MVA Form by the Supplier will be considered as part of the final approval.

Note: ‘Deferred’ will not be utilised on MVA forms from the External Supply Chain.



MVA Form Section BData cells with a red triangle in the top right hand corner contain guidance on completing the cells.


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Define the Plan

Rolls-Royce will manage MVA requests through the use of an implementation plan. This will ensure that change requests are worked expediently to completion. This approach will drive key deliverables and define the who, what and when as part of the process.

• The implementation plan shall:

- Incorporate the identified technical and business tasks

- Be to a level of detail appropriate to ensure the identified risks and tasks are managed

- Ongoing review of the plan will be as identified in Section B




WHAT:

• Step 3 consists of executing the implementation plan.

WHO:

• Supplier.

• Rolls-Royce MEP when instructed in Section B

• Additional Rolls-Royce resources are potentially engaged e.g. Labs, Engineering etc

HOW:

• By implementing the Plan and governance reviews as agreed in the Plan

INPUT:

• Business and technical verification tasks

• Implementation Plan

OUTPUT:

• Implementation Plan (Enacted)

• Executed business and technical verification tasks should be considered

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Manage Production Method / Fixed Process:Step 3 - Execute Plan



WHAT:

• Step 4 consists of review and acceptance of verification evidence

• Completion of business tasks

• Decision on sentencing implementation of the proposed Fixed Process Document

WHO:

• Manufacturing Engineer Purchase (interface with Supplier)

• Product Control Authority

• Engineering Control Authority

HOW:

• By completing MVA Form Section C

INPUT:

• Implementation Plan executed

• Verification evidence

OUTPUT:

• MVA Form (Section C Completed)

• Approval of Section C completes the MVA process with regards to RRES 9000017 | Proprietary Information | ©2019 Rolls-Royce

Manage Production Method / Fixed Process:Step 4 - Sentence Change (MVA Section C)


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Confirmation all verification tasks have been completed and review of the results of the verification tasks to enable sentencing of the proposed Production Method or Fixed Process Document.

When a change has been approved and parts manufactured, under RRES 90000 the proposed change has been implemented. To revert back to a previous Fixed Process Document requires submission of a new MVA.

Sentencing when limitation applied requiring task to be completed. (see next slide)

Confirmation all business implantation tasks have been completed and the business benefit / case driving the change has been achieved.Note: This may occur at a later date to sentencing of technical verification


Manage Production Method / Fixed Process:Step 4 - Sentence Change

MVA Form Section CData cells with a red triangle in the top right hand corner contain guidance on completing the cells.

8. Sentencing of Limitation Follow-Up:

3. Sentencing Technical Verification Tasks:


Signature: Date:


10. Revision Level:

12. Sentencing Business Implementation Tasks:






Name:

6. Method / Fixed Process Identifier: 7. Revision Level:

11. Approval Authority

9. Method / Fixed Process Identifier:




4. Limitation:



Method Verification Approval 1. MVA Reference (RR)

Section C - Sentencing of Tasks and Closure 2. MVA Reference (Supplier)

Approved for Implementation. Approved for Limited Implementation.

Approved. Approved with Limitation. Rejected.

Rejected

Approved. Rejected.


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Approved with Limitation:

The MVA could be approved with a limitation that will be quantity or time bound and may require the supplier to complete additional tasks to gain approval without limitation.

Examples of Limitations:

• Produced parts conform to the Product Definition, but equivalency has not been demonstrated. The method will not be implemented for ongoing production, but a limited quantity of specified parts can be released as saleable product

• Produced parts are non-conforming to the Product Definition and require concession approval for salvage to make conforming. The method will not be implemented for ongoing production, but a limited quantity of specified parts can be released as saleable product





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Alignment of Technical and Business Sentencing:

• When ‘3. Sentencing Technical Verification Tasks’ is 'Approved' and parts have been sold / are to be sold to a customer, then the proposed Fixed Process Document MUST be issued and ‘12. Sentencing Business Implementation Tasks’ MUST be 'Approved for Implementation’.If for example the business benefit has not been achieved and the manufacturer wants to revert to the previous Fixed Process Document, then '12. Sentencing Business Implementation Tasks' shall be 'Approved for Limited Implementation' and instruct the pre MVA Fixed Process Document to be up-issued to the next unassigned revision level.

• When 3. Sentencing Technical Verification Tasks is 'Approved with Limitation' and parts have been / are to be sold to a customer, then the proposed Fixed Process Document MUST be issued and ‘12. Sentencing Business Implementation Tasks’ MUST be 'Approved for Limited Implementation' and instruct the pre MVA Fixed Process Document to be up-issued to the next unassigned revision level.

• Providing no parts have been / are to be sold to a customer, then ‘12. Sentencing Business Implementation Tasks’ may be 'Rejected', even though '3. Sentencing Technical Verification Tasks' is 'Approved' or 'Approved with Limitation’.





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Document Restructure:

• A complete re-structure of RRES90000 to better group requirements and flow of document

• Introduction of the ‘Method Verification Approval’ terminology as the mechanism to approve a Fixed Process Document (FPD). This replaces the ‘Fixed Process Approval’ terminology

• Expanded allowances for editorial changes that do not require approval by Rolls-Royce Engineering (Appendix C & D)

• Elimination of the ‘MEC’ terminology. Operations or elements of operations are either subject to Rolls-Royce Engineering Control, ‘EC’, or they are not

• Updated definitions Section to align to current quality system requirement landscape

New Appendices:

• Appendix A – Fixed Process Document (FPD) Checklist

• Appendix B – Additional Control Requirements for Critical Products and Production Fan Blades

• Appendix C – Special Process and Non-Destructive Testing (NDT) EC Operation Change Exceptions

• Appendix D – Other EC Operation Exceptions


RRES 90000 Rev FOverview of changes



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Applicability: Aerospace

Title: Briefing Pack - Verification and Approval of a Fixed Process Document (RRES 90000)

Author: D. Hale Chief of ME External Supply Chain

Document Owner: D. Hale Chief of ME External Supply Chain

Version Number: 1

Issue Date and Change History:

19-October-2019 : Initial Issue


sabre briefing pack: method verification approval (fixed

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