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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
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.
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
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
2.
AS9100
3.
AS9110
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
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
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.
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
4 6 TotalJExpectedJImplimentationJTimeJinJDays Above illustration gives the details for PERT Activity Diagram.
96
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
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
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
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
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' ' ' ' ' ' ' '
'''''''''Process'steps/main'ac1vi1es'
Process'indicators' (how'many?)'
Process'objec1ves'/' Purpose'
Process'map'
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$$ Training$eec5veness$($6.2.2)$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ Personnel$ $ Who% owns % this% process,% who% works% in% this% process,% and%who%directly%assists%this%process?% % Responsibility$and$authority$($5.5.1)$ Competence$criteria$($6.2.1)$
Inputs%
Outputs%
Process%%
$ The$ customer s$ need$ is$ met$ at$ the$ characteris5c$level.$ A$sa5sed$customer$($8.2.1)$ Receives$ product$ from$ the$ process$ that$ conforms$ to$ the$ requirements$ in$ the$ input$($7.2.1)$
How?%
(Suppor5ng$Processes)$ How$is$this$process$controlled,$including$the$use$of$ $ procedures,$work$instruc5ons,$and$methods?$ Computer$equipment$ Control$of$produc5on$and$Service$provision$(7.5.1)$ support$processes$$ 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$ $
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.
((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((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/_____(
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
***
Compiled By:
! 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