Guide to implement AS9100 Rev C


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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.

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Guide to implement AS9100 Rev C

  1. 1.    Guide  for  implementing  AS9100  Rev  C  By  ASHISH  JUDE  MICHAEL,  MBA,  IIM  Shillong          
  2. 2. 2   Guide  for  implementing  AS9100  Rev  C    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.                              
  3. 3. Guide  for  implementing  AS9100  Rev  C   3      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              
  4. 4. 4   Guide  for  implementing  AS9100  Rev  C    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.  
  5. 5. Guide  for  implementing  AS9100  Rev  C   5    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   (MROs)   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  
  6. 6. 6   Guide  for  implementing  AS9100  Rev  C    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  
  7. 7. Guide  for  implementing  AS9100  Rev  C   7    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).    
  8. 8. 8   Guide  for  implementing  AS9100  Rev  C    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  and  click  on  the  "Register  to  get  Access"  link.    In  Brief:  Sl  No.   Standard   Applicable  Industries  1   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  equipment’s  or  components  such  as  stockiest  &  distributers.  5   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  
  9. 9. Guide  for  implementing  AS9100  Rev  C   9    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  
  10. 10. 10   Guide  for  implementing  AS9100  Rev  C    First  we  should  use  PPM  (Project  Priority  Matrix)  to  define  our  utmost  priorities  in  this  project.  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.  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.  A  (5)  B  (5)  C  (5)  D  (4)   E  (1)  F  (5)  G  (5)  H  (5)   I  (5)  J  (5)  K(3)  L(6)   M(6)  N(6)  O(6)  P(5)   Q(5)  R(4)  S(5)  T(5)     Constrain   Accept   Enhance    Time   ✖   ✔   ✖  Cost/Budget   ✖   ✖   ✔  Performance   ✔   ✖   ✖  
  11. 11. Guide  for  implementing  AS9100  Rev  C   11    Activity TaskOptimistic(Time((To)Pessimistic(Time((Tp)Most(Likely(time((Tm)Effective(Time((Te)Precedence(ActivityADerermine Quality Standard to beimplemented 4 6 5 5 NULLBAssemble Team,Purchase Standard &Select Registrar 4 6 5 5 AC Recruit Quality Manager 4 6 5 5 BD Assemble Team 3 5 4 4 CEPurchase Standard &SelectRegistrar 0.5 1.5 1 1 DFSet Targets & Schedule PeriodicalReviews 4 6 5 5 EG Review support Literature &Software 4 6 5 5 FH Make Strategy 4 6 5 5 GI Plan The Implementation 4 6 5 5 HJ Draft QMSP 4 6 5 5 IK Training 2 4 3 3 JL Prepare Level 2,3& 4 documents 4 8 6 6 KM Send to QM department for Checking 4 8 6 6 LNUpgrade documents & Get themapproved 4 8 6 6 MO Implement & Adhere to QMS 4 8 6 6 NP Internal Assesment 4 6 5 5 OQInvite Registrar/Auditor for Pre-Assesment 4 6 5 5 PR Implement feedback of Auditors 3 5 4 4 QS Registration Assessment 4 6 5 5 RTImplement suggestions &Improvements of Auditor 4 6 5 5 S96TotalJExpectedJImplimentationJTimeJinJDaysAbove  illustration  gives  the  details  for  PERT  Activity  Diagram.  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  
  12. 12. 12   Guide  for  implementing  AS9100  Rev  C    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 ImplementationXYZ Todays Date: Thursday(vertical red line)Project Lead:Start Date: Monday[42] First Day of Week (Mon=2): 2WBS TasksTaskLead Start EndDuration(Days)%CompleteWorkingDaysDaysCompleteDaysRemaining1ManagementResponsiblities CEO 1/2/12 1/25/12 24 100% 18 24 01.1Derermine QualityStandard to beimplemented 1/2/12 1/6/12 5 100% 5 5 01.2Assemble Team,PurchaseStandard & SelectRegistrar 1/7/12 1/11/12 5 100% 3 5 01.2.1Recruit QualityManager 1/12/12 1/16/12 5 100% 3 5 01.2.2 Assemble Team 1/17/12 1/20/12 4 100% 4 4 01.2.3Purchase Standard&Select Registrar 1/21/12 1/21/12 1 100%1.3Set Targets & SchedulePeriodical Reviews 1/21/12 1/25/12 5 100% 5 5 02Implementation TeamResponsiblities Manager Quality 2/2/12 2/24/12 23 100% 17 23 02.1Review support Literature&Software 2/2/12 2/6/12 5 100% 3 5 02.2 Make Strategy 2/7/12 2/11/12 5 100% 4 5 02.3 Plan The Implementation 2/13/12 2/17/12 5 100% 5 5 02.4 Draft QMSP 2/20/12 2/24/12 5 100% 5 5 02.5 Training 2/24/12 2/28/2012 3 100% 4 3 03DepartmentalResponsiblities Demartmantal Heads 3/1/12 3/28/12 28 100% 20 28 03.1Prepare Level 2,3& 4documents 3/1/12 3/6/12 6 100% 4 6 03.2Send to QM department forChecking 3/9/12 3/14/12 6 100% 4 6 03.3Upgrade documents & Getthem approved 3/16/12 3/21/12 6 100% 4 6 03.4Implement & Adhere toQMS 3/23/12 3/28/12 6 100% 4 6 04 QM Responsibility Quality Manager 4/2/12 4/27/12 26 100% 20 26 04.1 Internal Assesment 4/2/12 4/6/12 5 100% 5 5 04.2Invite Registrar/Auditor forPre-Assesment 4/7/12 4/11/12 5 100% 3 5 04.3Implement feedback ofAuditors 4/12/12 4/15/12 4 100% 4 4 04.4 Registration Assessment 4/17/12 4/21/12 5 100% 4 5 04.5Implement suggestions &Improvements of Auditor 4/23/12 4/27/12 5 100% 5 5 024/11/1130-Jan-1206-Feb-1202-Jan-1209-Jan-1216-Jan-1223-Jan-1227-Feb-1205-Mar-1212-Mar-1219-Mar-1216-Apr-1223-Apr-1230-Apr-1202/01/12Ashish Jude Michael13-Feb-1226-Mar-1202-Apr-1209-Apr-1220-Feb-12  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.    
  13. 13. Guide  for  implementing  AS9100  Rev  C   13    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.   It’s   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  
  14. 14. 14   Guide  for  implementing  AS9100  Rev  C    Customers  etc.  OTD  (On  Time  Delivery)  and  Risk  Mitigation  Plan  are  the  two  important  parameters,  which  are  specially  focused  in  AS9100  Rev  C.      ProcessName: ProcessOwner:Cri1calSuccessFactors: Startevent:EndEvent:ProcessInputResources/material(withwhat?)Processpersonnel(withwhom?)InterfacesforinputSupplierforprocess/PreviousprocessProcessindicators(howmany?)Processobjec1ves/PurposeProcess:Processsteps/mainac1vi1esBLANK PROCESS TURTLE DIAGRAMInterfacesforOutputProcessOutput Customerofprocess/NextprocessTOOLwhichcanhelpindefiningtheprocessasperRev.Candatoolforconduc1nginternalauditSWOTAnalysisProcessImprovementReferenceDocuments(how?)Processmap NotesHow?%How$is$this$process$controlled,$including$the$use$of$procedures,$work$instruc5ons,$and$methods?$Control$of$produc5on$and$Service$provision$(7.5.1)$Control$of$Produc5on$Process$changes$($$Control$of$Produc5on$Equipment,$Tools$and$SoGware$Programes($Nonconforming$product$procedure$($8.3)$Document$contorl/records(4.2.3/4)$%%%%%%%%%%%%%%%%What%Results%?%$Measurements/analysis$of$the$product$of$$this$process$and$of$this$process$effec5veness$Monitoring$and$measurement$$of$product$($8.2.4)$Customer$Sa5sfac5on$(8.2.1)$Monitoring$and$measurement$of$processes$(8.2.3)$Analysis$of$data$(8.4)$$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% owns %this%process,%who%works%in%this%process,%and%who%directly%assists%this%process?%%Responsibility$and$authority$($5.5.1)$Competence$criteria$($6.2.1)$Training$records$($6.2.2)$Training$effec5veness$($6.2.2)$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$(Who$Helps?$Departments$and$Individuals)$IT$HR$Logis5cs$$Sales$Quality$$Maintenance$$Personnel$Inputs%What%is%the%need%the%customer%of%this%process%has%and%what%are%the%requirements%to%meet%that%need?%Product$needs$to$be$produced$according$to:$Customer$requirements$($7.2.1)$Statutory/Regulatory$Requirements$($7.2.1)$Organiza5onal$requirements$($7.2.1)$Outputs%$The$ customer s$ need$ is$ met$ at$ the$characteris5c$level.$A$sa5sfied$customer$($8.2.1)$Receives$product$from$the$process$that$conforms$ to$ the$ requirements$ in$ the$input$($7.2.1)$Process%%(Suppor5ng$Processes)$$Computer$equipment$support$processes$$Training$Hiring/Firing$Purchasing$Processes$Materials$movement$Processes$Inspec5on$Calibra5ng$$The$term$procedure$and$processare$not$necessarily$synonymous.$A$$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.$
  15. 15. Guide  for  implementing  AS9100  Rev  C   15    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.  
  16. 16. 16   Guide  for  implementing  AS9100  Rev  C      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”.        QUALITY(MANAGEMENT/_____(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((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(fill(Table(1.(( Sl#No. Sample#Details Visual#Inspec4on#before#pull#testType#of#separa4ons#observed. Pull force Applied1 Plug(pin(sample(12 Plug(pin(sample(23 Plug(pin(sample(34 Plug(pin(sample(45 Plug(pin(sample(56 Socket(pin(sample(17 Socket(pin(sample(28 Socket(pin(sample(39 Socket(pin(sample(410 Socket(pin(sample(5Type#of#separa4on Deno4onSlip((Pull(out) AConductor(broken(in(crimp(area. BContact(broken(in(crimp(area. CConductor(broken(outside(crimp(area. DContact(broken(outside((crimp(area. EAny(other(defect((Specify(in(Remarks) FRemarks#Inspector(Name:(Staff(No(Operator(Name:(Staff(No:(
  17. 17. Guide  for  implementing  AS9100  Rev  C   17    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.  It’s  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.  
  18. 18. 18   Guide  for  implementing  AS9100  Rev  C    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.    
  19. 19. Guide  for  implementing  AS9100  Rev  C   19    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.        ***                                        
  20. 20. 20   Guide  for  implementing  AS9100  Rev  C    Compiled  By:        MBA from IIM Shillong with 5 Years of Experience inAerospace /Electronics Industry (Quality & Production)ASHISH JUDE MICHAEL!  5 years of experience in Quality, Manufacturing & SCMactivities of Aerospace /Electronics Industry.!  One Year MBA in International Business from IndianInstitute Of Management, Shillong and a MechanicalEngineering Graduate.!  Worked with companies such as Bharat Electronics Ltd, ITCLtd.!  Served clients such as Boeing, UTC, Indian Air Force, IndianNavy.!  Worked on prestigious Light Combat Aircraft (LCA) Projectwhich 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, LEANmanufacturing, SPC, Vendor Management, Process Improvement, Poka-Yoke,Benchmarking, FAI, Production Management, Cross Culture Team Management,Negotiation Skills.