QUALITY ASSURANCE INSTRUCTIONS TO SUPPLIERS

Q5B – 009L Issue 1 – June 2004 Page 1 of 6

QAIS NO: Q5B-009L

SUBJECT: PRE PRODUCTION RISK AVOIDANCE PROCEDURE

1. PURPOSE

1.1 This Instruction establishes the process to be followed to avoid risk toall parties, when resourcing parts/assemblies from one Supplier toanother.

1.2 The Risk Avoidance Process will ensure the true standard andadequacy of the tooling, Engineering data and the last Seriespart/assembly is determined prior to the release of the work packagefrom one Supplier to another. The new Supplier will be required to“buy off” the individual work package elements – this will includeacceptance of the tooling, Engineering data and defined Condition ofSupply. Implicit within the Suppliers acceptance of the part/tool/datacombination is the Suppliers guarantee that they havecapability/technology to manufacture the part as required to theCondition of Supply without modification and/or damage to the toolingprovided.

1.3 The Risk Avoidance Process introduces the concept of Last ArticleInspection Reporting and is intended to pre-empt and correct thoseissues often found at a stage in the part proving process which is oftenboth expensive, and difficult to resolve. It is intended to complimentand not, in any shape or form, replace the need for First ArticleInspection Reporting as defined within QAIS Q5B-009H “First ArticleInspection Reporting”.

2. SCOPE

2.1 This Instruction applies to, but is not limited to, all parts/assembliesbeing relocated from one Supplier to another and will be invoked bythe RA Contract/Purchase Order.

2.2 When necessary, referral to this document shall be included in theSubcontractor’s purchase orders to his outside sources and beapplicable in its entirety. The responsibility for embodying thisInstruction and undertaking individual specified tasks will be clearlydefined in the Project Quality Plan that is normally compiled for anystrategic resourcing of product.

2.3 This instruction details how the Pre Production Risk AvoidanceProcess is to be embodied including details of the process flow,facilities and resources required and the compilation of the Last ArticleInspection Report.

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3. REFERENCES

Form QSDC Nos. Q7B-564A, B, C, D and E “Last Article Inspection Report -Summary Sheet “, “Last Article Inspection Report - Continuation Sheet”, “LastArticle Inspection Report – Manufacturing/Inspection Equipment RecordSheet” “Condition of Supply Requirements Statement and AuthorisationSheet” and “Associated Tooling Health Statement” respectively.QAIS Q5B-007B “Personal Authorisation”. – QAIS Forms\Q7b564a.pdf, QAISForms\Q7B564B.pdf, QAIS Forms\Q7B127c.pdf, QAIS Forms\Q7B564D.pdf &QAIS Forms\Q7B564E.pdfSect7b.pdf

Q7B-009L Addendum – Compiling a Last Article Inspection Report

4. PROCEDURES

4.1 Applicability

As specified by the Contract involved in parts resourcing, the followingprocedures shall be invoked.

4.2 Pre Production Review Centre – see schematic layout (FigureOne)

4.2.1 A secure facility shall be established within the new Suppliers plant orat mutually agreed location which shall be known hereafter as the PreProduction Review Centre (PPRC). The PPRC is to be large enoughand organised in a manner to be able to receive and efficiently storeincoming tools, last series parts and associated Engineering data tomeet the demands of the Risk Avoidance process schedulerequirements.

4.2.2 The PPRC must be provided with an Inspection/Viewing area wherethe combination of individual last series representativeparts/assemblies, all associated manufacturing and inspection toolingand Engineering data can be correlated and a Last Article Inspection(LAI) held.

4.2.3 The PPRC will have an area designated for part/tool/data/LAI Reportscombinations which have successfully passed through the RiskAvoidance Process and have been “bought off” by the new Supplierand Raytheon Aircraft as acceptable for release to production.

4.2.4 The PPRC will also have provision made to “quarantine” any item be itpart, tool or item of data which cannot proceed into the “Accepted”area.

4.3 Series Last Article Part/Assembly (SLAP)

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4.3.1 The last part or assembly manufactured/assembled by the previousSupplier will be withdrawn from the normal supply route anddespatched to the Pre Production Review Centre. It is important torecognize that the Series Last Article Part/Assembly (SLAP) must betreated as a normal production item and may eventually be released bythe previous Supplier for normal production use by RAC. Where this isto be the case, provision must be made for the return of the SLAP tothe previous Supplier in a controlled and well understood manner.

4.3.2 Each SLAP must be accompanied by an appropriate ReleaseCertificate/Certificate of Conformity from the previous Supplier. Uponreceipt into the Pre Production Review Centre, the SLAP will be placedinto Quarantine and identified as such by attaching an appropriately designed “Quarantine” label attached to the part or assembly. TheLabel will detail the Part/Assembly number, the Part/Assembly Issueand the SLAP’s Batch/Serial number; the reason for Quarantine willstate “Series Last Article Part/Assembly”. Each SLAP will be carefullystored within the secure area until it is withdrawn for the LAI to beperformed.

4.3.3 Each SLAP will be correlated with its associated “Datapack” whichshall comprise of the requisite drawings, Engineering Planning,Condition of Supply. A blank LAI Report shall also be included withinthe Datapack awaiting the LAI activity

4.3.4 The entrance of the SLAP into the PPRC will be monitored on a Masterscheduled maintained by the PPRC staff to ensure the status andwhereabouts of the SLAP, Datapack and associated tooling is knownat all times and the LAI progress can be monitored.

4.4 Pre Production Review Centre Approved Staff

4.4.1 The PPRC shall be staffed by appropriately trained and qualifiedpersonnel approved by Raytheon Aircraft in accordance with theprocedures defined with QAIS Q5B-007B ”Personal Authorisation”.

4.4.2 The level of staffing and authorisations held must be considered inconjunction with the Project Programme requirements.

4.5 Last Article Inspection

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4.5.1 The SLAP (as identified in paragraph 4.3) will be fully inspected inconjunction with the tooling and associated Datapack to determine:-

� the accuracy and adequacy of sub-contracting planning andCondition of Supply/Purchase Order.

� the configuration standard is correct � correct material and/or parts have been used during

manufacture and/or assembly.� dimensional conformance to approved drawings, specifications,

appropriate reference standards and/or RAC approvedConditions of Supply.

� correct finish has been applied in conjunction with theDrawing/Condition of Supply.

� compliance with non-destructive test requirements.� conformance to functional test requirements.� item identification/part marking adequacy.� adherence to processing specifications including approved

processors.� adequacy of and/or need for check gauges/fixtures.� capability of tooling to produce acceptable parts.

4.6 Last Article Inspection Reporting

4.6.1 Details on how to complete the LAIR are given on the Addendum;.Sect Q7B -564 – Iss. 1 - addendum.doc - Click here to view

4.6.2 For LAIR Serial Numbering, the Raytheon Aircraft Supplier ApprovalCode for the NEW SUPPLIER (as it appears on the SubcontractorsApproval Certificate e.g. RAIFSAS/PART1/XXX) is to be used, followedby a sequential number, followed by year (last 2 digits) followed by theissue of the L.A.I.R. e.g. RAIFSAS/PART1/XXX/01/04 Issue 1.

4.6.3 In the event of a “Fail” being recorded against a particular attribute, thesubcontractor will complete the associated N.C./Remedial andCorrective Action Plan fields of the LAI Report Form. The proposedactions will be agreed and approved by the Raytheon Aircraft Qualityrepresentative assigned to oversee the Risk Avoidance Process.

4.7 Concluding the Last Article Inspection

4.7.1 Upon the successful completion of the Last Article Inspection, the newSupplier will have signed the LAIR in the fields as defined in theAddendum (see Para 4.5) to formally accept the tooling and associatedDatapack. Implicit with this “buy off” is the acknowledgement that thenew Supplier fully understands the requirements, thetooling/technology provided is compatible with their own and that theyare confident of producing the part/assembly at the rate required.

4.7.2 If the LAI proves to be unsuccessful, the SLAP/Tool/Datapackcombination will be placed within the PPRC Quarantine area pendingdisposition by Raytheon Aircraft. Appropriate disposition may requireboth MRB and Engineering Query action to be taken; similarly, adecision upon possible Disclosure to the Regulatory Authorities mayhave to be considered (see Para 4.5.3).

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Upon the successful conclusion of the reported anomaly, the newSupplier will be invited to buy the LAIR as detailed in Para 4.6.1.

4.8 Supplier Acceptance Pack

4.8.1 Once the new Supplier has accepted the LAIR for an individualPart/Assembly, a Supplier Acceptance Pack will be compiled. This willcomprise of the following documents:

1) Signed off copy of the requisite LAIR2) The associated Datapack (stamped as Uncontrolled - for reference

only)3) Any associated Engineering revisions4) signed copy of the Tool Transfer Note (to record formal handover ofthe tooling from RAC/previous Supplier to the new Supplier).

4.8.2 A copy of this Supplier Acceptance Pack will be forwarded to the new

Supplier; a copy will be retained by Raytheon Aircraft. The newSupplier will use this Pack as a useful reference source whenundertaking their own First Article Inspections.

4.8.3 The tooling for each SLAP will now be transferred to the hold areaawaiting shipment to the new Supplier. The SLAP, dependent upon thecontractual agreements made, may be returned to the normal supplychain, or “red banded” e.g. Sprayed with red paint and forwarded toRaytheon Aircraft/new Supplier as a “red banded master”.

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Figure One

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