Boeing Defense Space & Security

A Quality Management StudyBy Anas Shakil

Past Practices

Suppliers had a broad range of imposed requirements

Requirements varied by Commercial, NASA, and DoD Customers and even by branch of military service

As a result Boeing development sites evolved their own quality systems

D1-9000 AQS

D1-9000 BQS

SSP 41173NHB 5300.4 (1D2)

AS 9000

AQAP 110

ISO 9001/NHB 5300.4 (1B)

MIL-Q-9858 orEquivalent

AQAP 120

ISO 9002/NHB 5300.4 (1C)

MIL-I-45208 orEquivalent

DQS orEquivalent

LIMITED

CQS orEquivalent

This partial listing shows the most demanding to least demanding requirements in descending order

Advent of Quality Management System In its aim to target “One Quality System for the Boeing Company” Boeing

decided to adapt a new QMS based on a recent quality standard

AS9100, was one such standard published in November 1999 by the Society of Automotive Engineers (SAE). It was the first international quality system standard for the aerospace industry.

The International Organization for Standardization (ISO) Aerospace Technical Committee 20, in conjunction with the American Aerospace Quality Group (AAQG) in the United States and the European Association of Aerospace Industries (AECMA) in Europe and other countries including China, Japan, Mexico and Brazil, developed the quality system standard for use by aerospace companies.

It was the first single standard available for use across the global aerospace community and supplemented ISO 9000 requirements with those necessary to address civil and military aviation, and aerospace needs.

The IAQG agreed in March 2000 to align the requirements of ISO 9100, AS9100, PrEN 9100 and SJAC 9100 with the requirements ISO 9001: 2000.

The IAQG had established an international team to align the specific industry requirements contained within 9100 to the revised content and format of ISO 9001: 2000 version.

Comparison With ISO 9001: 1994 In addition to the requirements listed in ISO 9001: 1994, AS9100 also includes aerospace sector-specific requirements considered necessary to ensure the safety, reliability and quality of aerospace products. These include requirements in the areas of: Configuration management Reliability, maintainability and safety Design phase, design verification, validation and testing

processes Approval and review of subcontractor performance Verification of purchased product Product identification throughout the product's life cycle Product documentation Control of production process changes

Control of production equipment, tools and numerical control machine programs

Control of work performed outside the supplier's facilities Special processes Inspection and testing procedures Methods, resources and recording Corrective action Expansion of the internal audit requirements in ISO 9001 First article inspection Servicing, including collecting and analyzing data,

delivery, investigation and reporting; control of technical documentation

Review of disposition of nonconforming product.

AS9100, like its predecessor, AS9000, seeks to ensure customer satisfaction by having aerospace industry manufacturers produce world-class quality products at the lowest possible cost. AS9100 standardizes, to the maximum extent possible, the quality system requirements of the aerospace industry. Standardization of these requirements should result in cost savings to both vendor and contractor through the elimination or reduction of unique requirements developed for each different customer.

Difference and advantages over its predecessors Now different military products with different applications like

attack helicopters, surveillance aircrafts, SIGINT spotters, ICBMS all conform to one quality standard. Reduction in multiple expectations and a consistency in verification methodology. Both prime manufacturers and their suppliers are pleased with the results. Suppliers report a reduction in verification audits and an increased consistency in expectations. As a direct result, suppliers' customers are seeing a reduction in oversight costs and an improvement in supplier performance.

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, belief that how-to information stifles continuous improvement

Also the application over varied geopolitical environments is easy.

For example, regulatory requirements are critical functions within the industry. The requirements within AS9100 are complementary to contractual and applicable law and regulations.

Those implementing a quality system compliant with AS9100 must ensure that the additional requirements of their customers, regulatory agencies (such as the FAA and the JAA) and local, state and national laws are also referenced within the system's documentation.

Implementation of Product safety and quality control Manufacturing a product as sophisticated as an airplane or space

vehicle requires special attention during the production processes. It's important, for example, to ensure that the correct revision of the engineering documentation is being used and documented within the work instructions, and that work performance is recorded. This frequently requires a specific reference to the person performing the work. Controlling production processes is essential to demonstrate that operations have been correctly performed. This is especially important when conducting special processes that don't lend themselves to after-the-fact inspection techniques.

  The industry frequently relies upon tooling and other production

equipment, including computer-controlled machines, to fabricate and assemble products. This equipment often forms the basis for product acceptance. In these cases, it's essential to demonstrate the integrity of these tools and machines and to develop a process that will ensure adequate oversight of the entire process.

Aircraft are designed to perform for 50 years or more, and properly maintaining the aircraft is essential for continued safe operation. Thus, servicing requirements are an important part of the total quality system. These include maintenance and repair manuals as well as the actual servicing work. Again, record-keeping is important in documenting the work performed, the equipment used and the people doing the work.

  Some products require traceability of part or all of their

components. This requirement may be imposed by contract, regulatory agency or internal need. In any case, AS9100 provides the essentials of an effective traceability program.

Using measuring devices of known accuracy and this may include computer-assisted measuring and test equipment is essential in the verification process. Maintaining a calibration history of this equipment and documented proof that it's reviewed and verified periodically underlies the entire metrology system.

Diagnosing the quality management system's health and using this information to guide improvement activity is important for efficiency and effectiveness. Internal audits performed by competent personnel are a vital input into this health measurement system. AS9100 provides some additional expectations regarding internal quality audits.

Detailed first-article inspections are frequently performed to demonstrate product conformance to engineering requirements. Documenting the actual inspection and test results is an established method of demonstrating initial item acceptance. The standard provides general direction in this regard and suggests that AS/EN/JISQ9102 be consulted for further guidance. Another international aerospace standard, called AS9102 and developed by the IAQG, outlines a methodology for performing and documenting first-article inspections.

  When things don't go as planned, AS9100 gives directions for

controlling and disposing nonconforming material. This includes specific requirements for contacting the customer for authorization when using or repairing a product that doesn't conform to engineering requirements.

Shifting to the New Standard

The Boeing Quality Management System shall be:

All Boeing sites shall have a quality management system compliant to the new standard

Applicable Boeing suppliers quality system approval will be transitioned over a two year period to the “Boeing Quality Management System Requirements for Suppliers”

“ISO as supplemented by SAE AS9100”

D1-9000 AQS

D1-9000 BQS

SSP 41173NHB 5300.4 (1D2)

AS 9000

AQAP 110

ISO 9001/NHB 5300.4 (1B)

MIL-Q-9858 orEquivalent

AQAP 120

ISO 9002/NHB 5300.4 (1C)

MIL-I-45208 orEquivalent

DQS orEquivalent

LIMITED

CQS orEquivalent

BQMS(D6-82479)

13 Heritage Systems replaced with a single Boeing Quality Management System

BQMS has two Appendixes and two Addendum

Quality ManagementSystem (A)

AdvancedQuality System (1)

Inspection and TestQuality System (B)

SoftwareQuality System (2)

D1-9000 AQS

D1-9000 BQS

SSP 41173NHB 5300.4 (1D2)

AS 9000

AQAP 110

ISO 9001/NHB 5300.4 (1B)

MIL-Q-9858 orEquivalent

AQAP 120

ISO 9002/NHB 5300.4 (1C)

MIL-I-45208 orEquivalent

DQS orEquivalent

LIMITED

CQS orEquivalent

BQMS

APPENDIX A

APPENDIX B

The Top-Level Document

Quality Management System“ISO as supplemented by AS9100”

Inspection and Test Quality System

Mapping Guide for BQMS TransitionD1-9000 AQS

D1-9000 BQS

SSP 41173NHB 5300.4 (1D2)

AS 9000

AQAP 110

ISO 9001/NHB 5300.4 (1B)

MIL-Q-9858 orEquivalent

AQAP 120

ISO 9002/NHB 5300.4 (1C)

MIL-I-45208 orEquivalent

DQS orEquivalent

LIMITED

CQS orEquivalent

Appendix A: Quality Management System“ISO as supplemented by AS9100

Appendix B: Inspection and Test System

Quality Management SystemAppendix A

Appendix A will refer Supplier to SAE website and address for AS9100 ordering information.

The AS9100 is a copyrighted document and cannot be reproduced One ONE copy per person (electronic or hardcopy) within Boeing

Appendix A primarily imposed on suppliers of complex Boeing or Source Design product.

Inspection & Test Quality SystemAppendix B

Appendix B applies to suppliers requiring a basic inspection and test system & is based upon ISO 9002/3

Length of production runs, product complexity and consideration for product use are factors that determine when Appendix B is imposed.

Aerospace Industry has recognized need for “less than” document.

Advanced Quality SystemsAddendum 1

• This addendum is not a stand alone quality system and shall accompany in contract flow either Appendix A or B as applicable

• Addendum 1 is used when Key Characteristics are identified in Boeing design requirements and/or variation reduction techniques are desired

• Describes a process for continuous quality improvement

• It includes requirements that emphasize decreased cost through process control and variation reduction

Software Quality SystemAddendum 2

This addendum is not a stand alone quality system and shall accompany Appendix A as applicable

Applies to suppliers of software that: Is delivered with or as a part of Boeing products Supports the operation of Boeing products Is used to build, inspect, or test deliverable software products

Requirements are Appendix A as interpreted through ISO 9000-3

Status OF Shift to the new standard• Establish Ground Rules for Transition complete• Baseline Boeing Suppliers complete

– List supplier’s current Quality System level– Map to new Quality System level based company procedures

• Train Boeing Personnel complete• Advise suppliers of new requirements complete

– Commitment letter and response request mailed October ‘00• Suppliers Perform Transition in process• Validate Supplier Quality System ongoing

– Perform on-site assessment for compliance – Approve and update Boeing ASL

• Update PO/contracts to new requirement ongoing

Boeing Defense Space & Security Boeing has asked its supplier base to

transition from legacy quality systems such as D1-9000, MIL-Q-9858A, MIL-1-45298 and others, to the Boeing Quality Management System. Boeing is also walking the walk; its aircraft and missiles group and many other facilities are registered or currently in process.

Quality Issues and response of Boeing In 2005 F15 bought by South Korea had issues

in the jamming and self protection suites. Also some aircrafts bought off the shelf had cracks in their Air Frame.

This was brought to the attention of Boeing and US DoD.

Boeing agreed to provide replacements as an added unit in the Deal earlier discussed as spares were not available. The F 15s bought were different in terms that the self protection suites were not part of the Aircraft frame but were as added pods as compared to US F 15s, hence availablitiy of spares for maintenance was an issue.

Earlier one F 15 had crashed which was attributed to the quality issues, however Boeing refused to take responsibility as Koreans insisted on having a percentage of the Aircraft built with parts made by Korean companies.

The Korean companies had their own quality standards different from those that Boeing inspectors were familiar with, also in trying to impose their own standards in Korea and trying to maintain the delivery dates promised the first lot of Air Crafts had a considerable percentage of quality issues.

The South Koreans also pointed out that each aircraft had 65,000 components that might need to be repaired or replaced, which meant the 1,200 defective parts represented a part in every 1,667.

Boeing as a result promised to perform the work using its proven integrated logistics model, which combines supply chain forecasting; coordinated procurement of production and spare parts to benefit from economies of scale; rigorous supplier contracting, quality and risk-management practices; and more efficient delivery processes, as well as collaboration with customer maintenance depots and local industry.

In the End Moving from Old practices

PILOT: Aircraft handles funny.

Quality Engineer : Aircraft warned to straighten up, fly right, and be serious.