Guide

for implementing AS9100 Rev C

By
ASHISH JUDE MICHAEL, MBA, IIM Shillong

Introduction
I am writing this document to help out managers, who think AS9100 is a very complicated system to install, implement and follow. They have an apprehension that it requires tons of documentation and record keeping. I will be bringing the basic outlines of how to implement a QMS (Quality Management System) from scratch, which adhere to AS9100 Rev C requirements in a very basic manner. This document alone cannot be used to implement the AS9100 Rev C; the aim of this document is to familiarize the managers about the basics of implementation of AS9100 Rev C. I have used many illustrations and also used project management concept to implement AS9100 Rev C. I have used my own experience; I played an important role in implementing AS9100 Rev C in my SBU (Strategic Business Unit), which is EW&A (Electronics Warfare & Avionics) at Bharat Electronics. Our SBU was one of the first SBUs in India to get AS9100 certification among PSUs. Our Head of Team for Implementation of AS9100 was our QM (Quality Management) DGM Mr. Satyanarayana and I was a directly reporting to him. I will divide this document in 14 steps (These steps are inspired from How to implement AS9100?) and will be elaborating on each step and add if any thing is missing.
2

Guide for implementing AS9100 Rev C

Table of Contents

Management Responsibilities Step 1: Determine which Quality standard to adopted Step 2: Assemble the Team, Purchase the Standard & select registrar Step 3: Set targets and periodically review them Implementation Team Responsibilities Step 4: Review support literature and software Step 5: Make a strategy Step 6: Plan the implementation Step 7: Documentation Step 8: Draft QMSP (Level 1 Document) Step 9: Training Departmental Responsibilities Step 10: Level 2 , 3 & 4 level Documents Step 11: Implement & adhere to Quality Management System (QMS) QM Responsibility Step 12: Invite registrar/auditor for a pre-assessment Step 13: Gain registration Step 14: Continual assessment Conclusion Guide for implementing AS9100 Rev C
3

Management Responsibilities
Step 1: Determine which Quality standard to adopted This is a strategic decision to be taken by senior management. One should not seek certification for the sake of getting it. Understand how this will help you in a long run. AS9100 is necessity if you are planning to enter aerospace & defence industry or space industry. ISO9001 is just 70% of AS9100. Let me give you a brief introduction about various types of Certification you can go ahead. 1. ISO9001: is a quality standard maintained by the International Organization for Standardization (ISO) and is administered by accreditation and certification bodies like PRI Registrar. The rules are updated periodically to accommodate changes in the business environment. Some of the requirements include:

Procedures that cover all key practices in the business Monitoring those procedures to ensure effectiveness Keeping adequate records Checking output for defects, and implementing corrective actions as needed to Prevent recurrence if defects are found Periodic review of the overall quality management system and the processes within the system to measure effectiveness Implementing a continuous improvement program

When an organization is certified and found to be in conformance with ISO 9001 that organization may publicly state that it is "ISO 9001 certified" or "ISO 9001 registered". Certification to an ISO 9001 quality standard does not guarantee quality of end products and services; however, it certifies that formalized business processes are being applied. Although the ISO 9001 quality standard originated in manufacturing, it can be applied to a variety of products, not just physical objects, but products such as services or software.

Guide for implementing AS9100 Rev C

2. AS9100: is an aerospace standard based on the ISO 9001 quality system requirements. AS9100 takes the ISO 9001 requirements and supplements them with additional quality system requirements, which are established by the aerospace industry in order to satisfy DOD, NASA and FAA quality requirements. The intent of AS9100 is to establish a single quality management system for use within the aerospace industry. The standard was developed by Working Group 11 of ISO TC20 and was supported by the International Aerospace Quality Group (IAQG). The official title of AS9100 is "AS9100 Quality Management Systems - Requirements for Aviation, Space and Defense Organizations". The AS9100 standard is recognized worldwide, however, participating countries can use their own numbering conventions. For example, the standard was released as EN9100 in Europe. Regardless of the number, the standard should be identical in content. The industry has moved toward requiring their subcontractors and suppliers to be AS9100 compliant and/or certified. By becoming registered to AS9100 or by conforming to the standard, suppliers can gain a competitive advantage and benefit from the improved processes and continuous improvement that is the foundation of ISO 9001 certified Quality Management Systems. 3. AS9110: The AS9110 aerospace standard is based on AS9100 but adds specific requirements that are critical for the maintenance of commercial, private, and military aircrafts. This standard defines the quality system requirements based on AS9100 and includes additional criteria for maintenance repair and overhaul facilities (MRO's) serving the aircraft industry. The AS9110 standard was published by SAE International. It is formally titled "AS9110 Quality Maintenance Systems - Aerospace - Requirements for Maintenance Organizations" by the Americas Aerospace Quality Group (AAQG). The prime candidates to seek certification to the AS9110 standard are FAA 145 certified repair stations. Those seeking Parts Manufacturing Approval (PMA) from the FAA to manufacture aircraft parts and Guide for implementing AS9100 Rev C
5

components are also likely to seek AS9110 certification. Some of the areas of emphasis in the AS9110 standard include detecting and preventing counterfeit and suspect unapproved parts, human factors (recognizing human factors that affect workers), safety management systems, technical data, project management and risk management. 4. AS9120: Quality Management Systems - Requirements for Aviation, Space and Defense Distributors." is an aerospace standard based on AS9100 that adds specific requirements that are relevant for stockiest or pass-through distributors for the aerospace industry. SAE International published the AS9120 standard. This standard addresses chain of custody, traceability, control and availability of records. AS9120 would be applicable for organizations that resell, distribute, and warehouse parts found in aircraft and other aerospace components. The standard is not applicable to value-added distributors due to customer-product changes nor is it intended for organizations that rework or repair products. Organizations that perform work that affect or could affect product characteristics or conformity should use AS9100 or another general quality management system standard. AS9120 is based on ISO 9001 but it includes nearly 100 additional requirements specific to aerospace distributors. AS9120 provides suppliers with a comprehensive quality system focused on areas directly impacting product safety and reliability. Some of the areas covered in AS9120 include splitting (specific requirements for batch and lot splitting), control of records, traceability (tracking from receipt of product to delivery), and evidence of conformance (distributors must meet document specifications). 5. AS9003 The intent of the AS9003, Inspection and Test Quality System; is to ensure that the inspection, conformity and airworthiness of products are maintained. The AS9003 standard contains the minimum requirements for an Inspection and Test Quality System and was intended for use by small build/machine to print organizations. A quality system structured to include the
6

Guide for implementing AS9100 Rev C

AS9003 requirements provides the supplier with a system that defines activities necessary to support product integrity such as: 1. Management Responsibility 2. Documentation of the Quality System 3. Controlled Contract Review and communication of requirements to production 4. Document and Data Control 5. Purchasing: Guidelines for choosing 6. Control of Customer Supplier Product, tooling and raw materials 7. Product Identification and Traceability 8. Process Control - Methods for controlling manufacturing/build processes 9. Inspection and Testing, In-process, Final Inspections, Test and the associated documentation of status and results 10. Control of Inspection, Measuring and Test Equipment 11. Control of Nonconforming Product 12. Corrective Action processes 13. Handling, Storage, Packaging, Preservation and Delivery 14. Control of Records - Internal Quality Audits to monitor your system 15. Training # OASIS Database: The OASIS database is a product of the International Aerospace Quality Group (IAQG). OASIS houses supplier and audit assessment data for all companies who hold an accredited certification in any of the AQMS series of Standards (i.e. - AS9100, AS9110 and AS9120). The IAQG has set firm requirements regarding the inclusion of aerospace certified suppliers in the OASIS database. Simply put, it is not optional - if you hold an accredited certificate to AS9100, AS9110 or AS9120 - you must be entered into the OASIS database. SAE International document AS9104 details the Certification Bodies' requirements for Aerospace Certification Programs. We are bound by these requirements as stated on our aerospace certificates, "The audit was conducted in accordance with the requirements of SAE AS9104 Rev. A." (Reference SAE AS9104 - Requirements for Aerospace Quality Management System Certification / Registrations Programs). Guide for implementing AS9100 Rev C
7

Additionally, any supplier listed in the OASIS database must set someone up as the OASIS Administrator. This designated person will be the contact point with regards to OASIS, and is responsible for maintaining accurate supplier data in the system (i.e. - supplier name, address, etc.). This person is also the only contact who can grant access to view pertinent audit assessment details. An OASIS user cannot access audit data without first gaining permission from the suppliers' listed OASIS administrator. If any aerospace certified supplier refuses to be a part of OASIS, or refuses to set up an OASIS administrator, Certification Bodies are required by the IAQG to revoke the certificate of registration. The very first step to get involved with OASIS is to become a registered user. Anyone can become a registered user, and you do not need to hold an active aerospace certificate in order to become a user. Visit the OASIS database at http://www.iaqg.org/oasis and click on the "Register to get Access" link. In Brief:
Sl No. Standard Applicable Industries

ISO9001

All manufacturing and any industry from service to product based.

2.

AS9100

Specifically for organizations developing, manufacturing and selling aerospace equipments/components.

3.

AS9110

For organizations into maintenance & repairs (MRO) of Aircrafts.

4.

AS9120

For Organizations which sell & stock airborne equipments or components such as stockiest & distributers.

AS9003

For organizations which provide third party inspection or testing facilities for airborne equipments/components.

One has to be prepared for the cost of quality, which will be high during initial phase of 3-4 years but after that you can reap the benefits in the long run. But if
8

Guide for implementing AS9100 Rev C

you are into Aerospace & Defence /Space business, AS9100 is critical for your future. For implementing AS9100 senior management should support its Quality Management Department to fullest. Initially things will be difficult to implement but perseverance pays off, you have to understand Rome was not built in a Day and so is for AS9100 implementation. Unless you adhere it from within the organization its difficult to maintain. Step 2: Assemble the Team & Purchase the Standard The road to implementing starts with assembling the right team. Depending upon your organization, you can make an official of a rank DGM/AVP/Manager to head of team, the team should be cross-functional with employees representing each department. Head of team should have first hand experience of implementing AS9100 and has good personal skills. Provide him necessary resources. Try to visit the companies, which have already established AS9100 certified systems, have a look on their processes. Next thing is to purchase the Standard, and to select a registrar such as UL etc. Consult the registrar whenever it is required so. Give enough time for the team to understand the standard, the standard itself is vast and requires lots of time to read all the clauses and requirements. Step 3: Set targets and periodically review them Set the targets for Implementation team and review them periodically to ensure that we are on right track and this will also help the team to put forward their requirements or suggestions where senior management can help them. I suggest we should apply project management concept while implementing AS9100 Rev C. Lets define: Project: AS9100 Rev C Implementation

Guide for implementing AS9100 Rev C

First we should use PPM (Project Priority Matrix) to define our utmost priorities in this project. Time Cost/Budget Performance Constrain Accept Enhance For example in given illustration of PPM maximum priority is given to performance then comes time and finally cost/Budget. This means we want that we have to by all means improve systems to implement AS 9100 Rev C and it may take a little bit more time and we want to reduce the cost by saving more, provided we are successful in implementing our project AS9100 Rev C.

A (5)

H (5)

I (5)

P(5)

Q(5)

B (5)

G (5)

J (5)

O(6)

R(4)

C (5)

F (5)

K(3)

N(6)

S(5)

D (4)

E (1)

L(6)

M(6)

T(5)

Above is the PERT Activity Diagram, is gives the activities and gives the most effective time for each activity. You can refer the illustration in figure, which defines this PERT Network Diagram.

10 Guide for implementing AS9100 Rev C

Activity A B C D E F G H I J K L M N O P Q R S T

Derermine Quality Standard to be implemented Assemble Team,Purchase Standard & Select Registrar Recruit Quality Manager Assemble Team Purchase Standard &Select Registrar Set Targets & Schedule Periodical Reviews Review support Literature &Software Make Strategy Plan The Implementation Draft QMSP Training Prepare Level 2,3& 4 documents Send to QM department for Checking Upgrade documents & Get them approved Implement & Adhere to QMS Internal Assesment Invite Registrar/Auditor for PreAssesment Implement feedback of Auditors Registration Assessment Implement suggestions & Improvements of Auditor

Task

Optimistic( Pessimistic( Most(Likely( Effective( Time((To) Time((Tp) time((Tm) Time((Te) 4 4 4 3 0.5 4 4 4 4 4 2 4 4 4 4 4 4 3 4 6 6 6 5 1.5 6 6 6 6 6 4 8 8 8 8 6 6 5 6
5 5 5 4 1 5 5 5 5 5 3 6 6 6 6 5 5 4 5 5 5 5 5 4 1 5 5 5 5 5 3 6 6 6 6 5 5 4 5 5

Precedence( Activity NULL A B C D E F G H I J K L M N O P Q R S

4 6 TotalJExpectedJImplimentationJTimeJinJDays Above illustration gives the details for PERT Activity Diagram.

96

Implementation Team Responsibilities

Step 4: Review support literature and software provided with Standard There are a large number of tools that can be very helpful at every stage of the process of implementing AS9100 there are many suggested formats, which we have to modify as per requirement. We have to segregate the formats which we can use as it is and on which we have to do some modification. Step 5: Make a strategy I again will stress, process towards implementing AS9100 must start with commitment from top management. As part of this, an organizational strategy should be developed, and an implementation by the team formed. Think of constrains which you are going to face and find the solutions before Guide for implementing AS9100 Rev C 11

hand. Its better to spend more time in planning and perfecting the things than rush into implementation phase and mess up the things. Step 6: Plan the implementation
AS9100 Rev C Implementation
XYZ Project Lead: Ashish Jude Michael Start Date: 02/01/12
[42]

Today's Date:

24/11/11
(vertical red line)

Thursday

Monday First Day of Week (Mon=2): 2

06 - Feb - 12 13 - Feb - 12 20 - Feb - 12 27 - Feb - 12 05 - Mar - 12 12 - Mar - 12 19 - Mar - 12 26 - Mar - 12 02 - Apr - 12 09 - Apr - 12 16 - Apr - 12 23 - Apr - 12 02 - Jan - 12 09 - Jan - 12 16 - Jan - 12 23 - Jan - 12 30 - Jan - 12 30 - Apr - 12

WBS 1

1.1

1.2 1.2.1 1.2.2 1.2.3 1.3 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 4.5

Tasks Management Responsiblities Derermine Quality Standard to be implemented Assemble Team,Purchase Standard & Select Registrar Recruit Quality Manager Assemble Team Purchase Standard &Select Registrar Set Targets & Schedule Periodical Reviews Implementation Team Responsiblities Review support Literature &Software Make Strategy Plan The Implementation Draft QMSP Training Departmental Responsiblities Prepare Level 2,3& 4 documents Send to QM department for Checking Upgrade documents & Get them approved Implement & Adhere to QMS QM Responsibility Internal Assesment Invite Registrar/Auditor for Pre-Assesment Implement feedback of Auditors Registration Assessment Implement suggestions & Improvements of Auditor

Task Lead CEO

Start
1/2/12

End
1/25/12

24

100%

18

24

1/2/12

1/6/12

100%

1/7/12 1/12/12 1/17/12 1/21/12 1/21/12 Manager Quality 2/2/12 2/2/12 2/7/12 2/13/12 2/20/12 2/24/12 Demartmantal Heads 3/1/12 3/1/12 3/9/12 3/16/12 3/23/12 4/2/12 4/2/12 4/7/12 4/12/12 4/17/12 4/23/12

1/11/12 1/16/12 1/20/12 1/21/12 1/25/12 2/24/12 2/6/12 2/11/12 2/17/12 2/24/12 2/28/2012 3/28/12 3/6/12 3/14/12 3/21/12 3/28/12 4/27/12 4/6/12 4/11/12 4/15/12 4/21/12 4/27/12

5 5 4 1 5 23 5 5 5 5 3 28 6 6 6 6 26 5 5 4 5 5

100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

3 3 4

5 5 4

5 17 3 4 5 5 4 20 4 4 4 4 20 5 3 4 4 5

5 23 5 5 5 5 3 28 6 6 6 6 26 5 5 4 5 5

Quality Manager

Use the scheduling tools as Gantt chart to schedule the implementation. Better to go through modular approach. Which means implement in phases. First concentrate on management Responsibilities then comes Implementation Team Responsibilities next comes departmental responsibilities and finally the Quality Management Responsibilities in last phase. In the above figure I have shown an example of scheduling of activities for AS9100 implementation. Once Implementation plan is ready its time to start documentation. But first of all QMSP (Quality Management System Procedure) should be drafted before going into department level.

12 Guide for implementing AS9100 Rev C

Days Remaining
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Duration (Days)

Days Complete

Working Days

% Complete

Step 7: Documentation In AS9100 we generally follow four levels of documentation.

1. Level 1: An Organizational level Quality Manual: We can call it a QMSP (Quality Management System Procedure). If it is too big you can make it in volumes. It is a controlled copy, and must clearly define the Major Quality Procedures followed by each department in an organization. Its the responsibility of Head of Implementation of AS9100 team to get inputs from the department heads and formulate. Its like a Master document for the QMS (Quality Management System). It should contain the generalized procedures and formats such as CA/PA (Corrective Action /Preventive), Engineering Change Request (ECR), Approved Deviation, Process Improvement, Document Upgrading Requirement etc. We should also give details about the yearly cycles of periodic assessments both internal and external. 2. Level 2: Department level Quality Documents: This includes the Turtle Charts; Risk Mitigation plans for each department. Turtle chart is a one-page document, which defines the all the activities in a department as process. There are inputs/Outputs, Process, Targets, Suppliers, and

Guide for implementing AS9100 Rev C 13

Customers etc. OTD (On Time Delivery) and Risk Mitigation Plan are the two important parameters, which are specially focused in AS9100 Rev C.
BLANK PROCESS TURTLE DIAGRAM
Process'Name:' Cri1cal'Success'Factors:' Process'Owner:' Start'event:' End'Event:' Process'Input' ' ' ' ' ' Interfaces'for' input' ' ' ' ' ' ' ' SWOT' Analysis' ' Resources/material' (with'what?)' Process:' Process'personnel' (with'whom?)' Process' Output' ' ' ' ' Interfaces'for' Output' ' ' ' ' ' ' '

Supplier'for' process'/' Previous' process'

'''''''''Process'steps/main'ac1vi1es'

Customer'of'' process'/' Next'process'

Process'indicators' (how'many?)'

Process'objec1ves'/' Purpose'

Process'map'

Reference'Documents'(how?)' ' '

Process' Improvement' '

Notes'

TOOL''which'can'help'in'dening'the'process'as'per'Rev.C'and'a'tool'for'conduc1ng'internal'audit'

with%What%?% What%are%the%Materials,%Equipment%and%other%resources%needed%by% this%process?% Plant$and$machinery$(6.3)$ Process$equipment$($6.3)$ Measuring$equipment$(7.6)$ Packaging$Storage$(7.5.5)$ Customer$Property$(7.5.4)$ Transporta5on$of$materials$in$this$process$(6.3)$ Raw$materials$needed$in$this$process($7.4)$

with%%Who%?% (Who$Helps?$ Departments$and$ Individuals)$ IT$ HR$ Logis5cs$$ Sales$ Training$records$($6.2.2)$ Quality$$ Maintenance$$ Training$eec5veness$($6.2.2)$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ Personnel$ $ Who% owns % this% process,% who% works% in% this% process,% and%who%directly%assists%this%process?% % Responsibility$and$authority$($5.5.1)$ Competence$criteria$($6.2.1)$

Inputs%

What%is%the%need%the%customer%of%this%process% has%and%what%are%the%requirements%to%meet% that%need?% Product$needs$to$be$produced$according$to:$ Customer$requirements$($7.2.1)$ Statutory/Regulatory$ Requirements$($7.2.1)$ Organiza5onal$requirements$($7.2.1)$

Outputs%

Process%%

$ The$ customer s$ need$ is$ met$ at$ the$ characteris5c$level.$ A$sa5sed$customer$($8.2.1)$ Receives$ product$ from$ the$ process$ that$ conforms$ to$ the$ requirements$ in$ the$ input$($7.2.1)$

How?%

(Suppor5ng$Processes)$ How$is$this$process$controlled,$including$the$use$of$ $ procedures,$work$instruc5ons,$and$methods?$ Computer$equipment$ Control$of$produc5on$and$Service$provision$(7.5.1)$ support$processes$$ Control$of$Produc5on$Process$changes$($7.5.1.2)$ Training$ Control$of$Produc5on$Equipment,$Tools$and$ Hiring/Firing$ SoGware$Programes(7.5.1.3)$ Purchasing$Processes$ Nonconforming$product$procedure$($8.3)$ Materials$movement$ Document$contorl/records(4.2.3/4)$ Processes$Inspec5on$ Calibra5ng$ $

%%%%%%%%%%%%%%%%What%Results%?% $Measurements/analysis$of$the$product$of$ $this$process$and$of$this$process$eec5veness$ Monitoring$and$measurement$$ of$product$($8.2.4)$ Customer$Sa5sfac5on$(8.2.1)$ Monitoring$and$measurement$of$processes$(8.2.3)$ Analysis$of$data$(8.4)$$

The$term$procedure$and$process'are$not$necessarily$synonymous.$A$$procedure$may$be$one$way$to$describe$a$$process$in$text;$however,$most$organiza5ons$have$many$more$ processes$than$the$procedures$required$by$the$standard.$

14 Guide for implementing AS9100 Rev C

The beauty of turtle diagram is that you can see the overall holistic view of a department and can be represented on a single sheet of paper concise , complete and crisp. We can define entire department as a process, we can clearly see in the above illustration. A unique reference number should link all Level 2 documents to QMSP, which reflect the revision number and date of revision. 3. Level 3 Documents: Process Definition Documents (PDDs), Standard Operating Procedures (SOPs),Work Instructions (WI): These are basically the set of documents, which are used by operators to perform various processes. These are made & controlled by related section head or process engineer but approved by Quality Management Department. 4. Level 4 Documents: Checklists, Process Validation Reports & PRCs (Product Route Card)/OARCs (Operation Analysis Route Card): These are mostly the records maintained to keep control on product/process quality and traceability. Traceability is very important parameters, which is required for Aerospace Products as they are very critical. By looking a batch number or SL. No of a product we should be able to find all related checklist, PRC (Product Route card)/OARC (Operation Analysis Route Card) and reports with details as who was the operator and who was the inspector responsible. The difference between PRC & OARC is that PRC only records the details of the precedence activities done on project and by whom. Where else OARC is an ERP generated document, which gives instructions and also records the details of the precedence activities done on project and by whom.

Guide for implementing AS9100 Rev C 15

((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((Ref:(No:(12345Crimp/CKL/V(0(( (((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((Date:( Crimping(Tool(Part(No:. ( ( (Tool(Sl.No.( Locater(PN: ( ( ( (Locater(PosiLon:( Contact(PN: ( ( ( (Wire(Size( UTM(Asset(No:. ( ( (((((((((((((((((((((((((((((((((((((UTM(CalibraLon(Date:( ( Procedure:( 1.Annexure(1((Crimping(Process(validaLon(((Ref(PQRS/ABC/QP/IXYZVO:(dt:( 2.(Five(samples(of(plug(to(be(crimped.( 3.(Five(samples((of(socket(pins(to(be(crimped.( 4.(Every(week(on(Monday(this(acLvity(to(be(done.( 5.(A^er(Samples(are(collected(they(are(to(be(sent(to(MTD,(QA(for(pull(test(with(SAP(request.( 6.(Collect(the(reports(from(MTD,QA(and(verify(if(they(are(meeLng(the(requirements(and(collect(the(samples.( 7.(If(reading(are(meeLng(proceed(to(next(step(els(go(to(step(1(and(repeat(the(acLvity(unless(required(results(are(achieved.( 8.(Visually(inspect(the(samples(before(pull(test(and(mark(them(with(SL.Nos.( 9.Insepct(the(samples(a^er(pull(test(and(ll(Table(1.( ( Sl# Visual#Inspec4on# Type#of#separa4ons# Sample#Details Pull force Applied No. before#pull#test observed. Remarks# 1 Plug(pin(sample(1 2 Plug(pin(sample(2 3 Plug(pin(sample(3 4 Plug(pin(sample(4 5 Plug(pin(sample(5 6 Socket(pin(sample(1 7 8 9 10 Socket(pin(sample(2 Socket(pin(sample(3 Socket(pin(sample(4 Socket(pin(sample(5 Deno4on A B C D E F

QUALITY(MANAGEMENT/_____(

Type#of#separa4on Slip((Pull(out) Conductor(broken(in(crimp(area. Contact(broken(in(crimp(area. Conductor(broken(outside(crimp(area. Contact(broken(outside((crimp(area. Any(other(defect((Specify(in(Remarks)

Inspector( Name:( Sta(No(

Operator( Name:( Sta(No:(

Above illustration shows a sample checklist, which fulfills all requirements of AS9100 Rev C. All level 3 & 4 documents needed to be upgraded as and when the product requirement change. All these documents are to be linked to Level 3 & 4 documents by a unique reference number, which reflect the revision number and date of revision. All Level 1, 2 ,3 & 4 documents are controlled copies and are needed to be controlled by designated authority that will be responsible for them. Also they are auditable and the documents are to be retained for a minimum period of 5 years or as defined in P.O. (Production Order) terms by customer which ever is minimum. All documents needed to be complete and ensured that no loopholes are left. It is said for AS9100 documentation They say what you do and you do what they say.

16 Guide for implementing AS9100 Rev C

Step 8: Draft QMSP (Level 1 Document) Take help of department heads and give responsibility to each related team member of related department to formulate module for his/her department. Its the responsibility of Team Lead/Head to verify and compile the QMSP as a complete document. Once QMSP is finalized discuss it with the registrar/auditor and take his feedback. Step 9: Training Plan for awareness training for the entire organization, better to be done in modules such as for QM, Production Control, Engineering, Manufacturing, Marketing, Material management, Plant Maintenance, Finance, Purchase, Sub- contract & Human Resource etc. Better keep QM all levels (1,2 &3) documents ready so that they may use them as sample documents and related persons can make their own level 2 & 3 level documents. Step 10: Level 2 ,3 &4 level Documents These documents are to be prepared by related department heads & process/line in-charge or engineers. It is responsibility of the representative of department in AS9100 implementation team to scrutinize and help in development of these documents. Step 11: Implement your Quality Management System Once the foundations have been laid, you should implement your quality management system. Its important that you make the process owners and the operators believe in the new system. They should be trained and told how it will beneficial for them. AS9100 requires lots of records to me maintain and the operators and process owners have lot of Inertia to do. They think it is done to keep check on them and will be used as evidence against them. Guide for implementing AS9100 Rev C 17

We should make them very clear that it is only for process improvement. AS9100 gives us process approach. We should always remember no operator or process owner commits a mistake deliberately is always a loophole in process, which has made him commit mistake, so make process perfect. If you can understand the above statement you got the real understanding of AS9100 that its never about product/people its only about process you follow. Step 12: Invite registrar/auditor for a pre-assessment A pre-assessment normally takes place about 6 weeks into the implementation of the quality system. The purpose of the pre-assessment is to identify areas where you may not be operating to the standard. This allows you to correct any areas of concern you may have before the initial assessment. Take their feedback and implement. Step 13: Gain registration Once the preparation and implementation has been completed, registration to the standard can take place. The key to this is a registration assessment. During this process, the registrar will comprehensively review your management system, and should you pass, you will be recommended for registration and be awarded your certificate. You need a Management Representative on behalf of senior management he may be an Additional General Manager/ COO. Certification allows you to advertise your success and promote your business and its commitment to quality management. Step 14: Continual assessment Maintaining your registration requires only that you continue to use and be committed to your quality system. This will be periodically checked by your registrar it can be done bi-annually or annually. But number of man-days fixed for a year for assessment is constant.
18 Guide for implementing AS9100 Rev C

Beside that you need to do minimum of two internal audits as per the schedule or frequency defined in QMSP. Once you are certified you will receive a score and you should always try to improve upon the score. You can use the AS9100 certified logo and show the entire industry about your capabilities. Conclusion: I sincerely hope that this document has definitely brought some clarity about the process of implementing AS9100 Rev C in your own organizations, cleared some apprehensions about AS9100 Rev C. One thing I will assure you that if you implement AS9100 Rev C and make the install systems that meet the requirement, life will be very easy for you. Initial cost of implementation can be a bit high but you can see the returns within 5 years. One of the best ways to maintain AS9100 Rev C system is by implementing ERP systems. It will reduce your record keeping and standardize the processes as well. Guide for implementing AS9100 Rev C 19

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Compiled By:

ASHISH JUDE MICHAEL

MBA from IIM Shillong with 5 Years of Experience in Aerospace /Electronics Industry (Quality & Production)

! 5 years of experience in Quality, Manufacturing & SCM activities of Aerospace /Electronics Industry. ! One Year MBA in International Business from Indian Institute Of Management, Shillong and a Mechanical Engineering Graduate. ! Worked with companies such as Bharat Electronics Ltd, ITC Ltd. ! Served clients such as Boeing, UTC, Indian Air Force, Indian Navy. ! Worked on prestigious Light Combat Aircraft (LCA) Project which is of national importance. Skill Set: TQM, AS9100, ISO14001,ISO9001,AS9102, 8D, SPSS, Mini-Tab, PPAP,FMEA, GAP Analysis, APQP, RRCA, Quality Clinic, Project Management, Kaizen, LEAN manufacturing, SPC, Vendor Management, Process Improvement, Poka-Yoke, Benchmarking, FAI, Production Management, Cross Culture Team Management, Negotiation Skills.

20 Guide for implementing AS9100 Rev C