PEN will provide the training and facilitation to link the clients ISO 9001-2008 compliant quality management system to achieve full compliance with the AS9100.
Upon completion of this program, the client will be AS9100 certified
Initially released in October 1999 by the Society of Automotive Engineers in the Americas and the European Association of Aerospace Industries in Europe, and shortly thereafter by standards organizations in Japan and Asia, AS9100 was a cooperative effort of the International Aerospace Quality Group. As such, it combines and harmonizes requirements outlined in the SAE’s AS9100 and Europe’s prEN9000-1 standards. Recently, AS9100 was revised to align with ISO 9001:2000
AS9100, Aerospace Basic Quality System Standard, was developed by a group of US aerospace prime contractors, including Allied-Signal. Allison Engine Company, Boeing, General Electric Aircraft Engines, Lockheed Martin. McDonnell Douglas, Northrop Grumman, Pratt Whitney, Rockwell Collins, Sikorsky Aircraft, and Hamilton Sundstrand. Significantly, the US government was not actively involved in the AS9000 standard’s development. AS9000 was developed and issued under the auspices of the Society of Automotive Engineers.
Although the standard outlines industry “whats” for a quality management system, the “how tos” were deliberately left out and remain the system designers’ responsibility. This reflects the AS9100 writing team’s, and my, belief that how-to information stifles continuous improvement.
The effective implementation of this model gives your company the great competitive advantage of having the discipline to identify, understand, and fully meet your customers’ needs, requirements, and expectations, and effectively drives down waste and production costs, while providing the quality and safe products that your customers demand. This allows you to increase your customers’ satisfaction, thus leading to increased demand and market share.
II. AS9100 requirements
The AS9100 standard contains all elements of the ISO 9001:2008 standard, including its corresponding guidelines. In addition, specific items have been added to the AS9100 standard to support the unique quality and reliability needs of the aerospace industry.
AS9100 requires that an organization establish and document a configuration management process. Variations to “key characteristics” of a product must be managed for product fit, performance, service life and manufacturability.
PEN will provide the training and facilitation to link the clients ISO 9001-2008 compliant quality management system to achieve full compliance with the AS9100. This will include:
• Planning product realization for effective and efficient processes. The standard emphasizes planning for in-process verification when a product can’t be verified at a later point. Tooling design must also be considered when process control methodology is used to ensure that process data will be captured.
• Plan for design-and-development activities and ensure interim control points during the design process. Design outputs are supplemented to provide identification of key characteristics. The data essential for the product that will be identified, manufactured, inspected, used and maintained is detailed.
• AS9100 provides information on areas of design-and-development verification documentation and validating testing and results.
• AS9100 includes a number of additional expectations for identifying and maintaining suppliers. Supplier approval is just one step in the process of managing suppliers.
• Seven communication requirements are detailed, ranging from clarifying engineering requirements to managing test specimens and right of access to suppliers’ facilities.
• The means by which a company examines and then accepts products from suppliers is detailed for supplier control. An organization might conduct a receiving inspection, perform the inspection at the supplier’s facility or formally delegate product acceptance to the supplier.
The customer’s supplier (clienta) is responsible for managing its suppliers and sub-tier suppliers according to AS9100. This includes performing special processes that are frequently subcontracted to processing houses. The supplier must use customer-approved sources; however, ensuring that the processing is properly performed is the supplier’s responsibility.
III.The following will define the training and facilitation to be provided in this program:
1. AS9100 Document Review Workshop TBD hours
This is the first step in assessing your quality management system. The PEN Instructor will lead the clients’ Leadership Team to compare the clients’ documented system with the requirements of the AS9100 standard.
2. AS9100 Documentation Workshop TBD hours
The AS9100 Documentation Workshop has two main goals:
• The documented system is AS9100 compliant
• The documented system reflects actual client practice.
3. AS9100 Internal Auditor Training TBD hours
The AS9100 audit process involves interviewing employees at all levels and reviewing records. Our purpose is to document with objective evidence the system’s effectiveness. PEN will train selected personnel from within the “clients’ staff to:
• Be fully knowledgeable in AS9100 requirements
• Be able to conduct an AS9100 internal audit effectively
4. AS9100 Implementation TBD hours
This course will provide plant wide training to:
• Train all client employee’s in AS9100 requirements
• Define all policies and procedures effecting their area
• Define implementation strategy
• Facilitate implementation
IV. Training Segments, estimates and target employees (assumes ISO 9100:2008 status)
|Step 1: Background and Overview of Quality Management System||Management|
|Step 2: Introduction to the AS9100 Quality Management System||All Employees|
|Step 3: Additional requirements for AS9100||Management; Quality|
|Step 4: Gap Analysis: assessment of existing ISO system and compare to the requirements of the AS9100 system||Management, Quality|
|Step 5: Action plan||Quality|
|Step 6: Management Review Committee||Management|
|Step 7: Develop System Level Procedures||Quality|
|Step 8: Complete Quality manual||Quality|
|Step 9: Internal audit training||Internal Auditors|
|Step 10: Pre-assessment||Management|
|Step11: Corrective action||Management|
|Step 12: Registration compliance audit||Management|
V. AS9100 -Training Implementation Sample Timeline
Week 1-3; Step 1, 2 and 3
Week 4-6; Step 4 and 5
Week 7-9: Step 6 and 7
Week 9-12: Step 8 and 9
Week 12-15: Step 10, 11 and 12