quality systems – the bedrock of your quality efforts
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Quality Systems – The bedrock of your quality efforts. Alan Daniels Montreal, Canada October 10, 2013. 1. Meeting Purpose. How your quality systems program can be a key element to help you company achieve your quality objectives. 2. Presentation Outline. Requirements Strategy - PowerPoint PPT PresentationTRANSCRIPT
Quality Systems –The bedrock of your quality effortsAlan DanielsMontreal, CanadaOctober 10, 2013
1
How your quality systems program can be a key element to help you
company achieve your quality objectives
Meeting Purpose
2
Requirements Strategy Team Leadership Publications Standard Activity ISO Liaison 9100 Series Revision Plan
Presentation Outline
3
IAQG Strategic Focus
Aligned to Address Challenges
Relationship Growth Strategy• Civil Authorities - Production • Space• Defense• Maintenance, Repair & Overhaul• Trade Associations
ImprovementStrategy
• Requirements
• People Capability • Product & Supply
Chain Improvement
• Performance
IAQG Operating Management SystemIAQG Other Party Management Team
Integration Team
3 Axes
4
EAQGLeader: Judy LASLEY
(Rolls Royce)
AAQGLeader: Buddy CRESSIONNIE
(Lockheed Martin)
APAQGLeader: Tatsuya SHIRAI
(Kawasaki Heavy Industry)
Mentor: Judy LASLEY (Rolls Royce)
IAQG Leader: Alan DANIELS (Boeing)
IAQG Document Representatives9100 : Alan Daniels (Boeing)9101 : Masahiro KAWAMOTO (MHI)9102 : Kevin WARD (Goodrich/UTC)9103 : Bernard LAURAS (Airbus)9104-1 : Mike ROBERTS (Boeing)9104-2 : Tim LEE (Boeing)9104-3 : Will TATE (Triumph)9107 : Ed BAYNE (Boeing)9110 : Agathe MOLL (Airbus)9114 : Ed BAYNE (Boeing)9115 : Raymond WRIGHT (Raytheon)9116 : Mike QUINN (Boeing)
IAQG Requirements Team
5
IAQG Document Representatives9117 : Jan SOMMARBERG (Volvo)9120 : Dale GORDON (Aerojet)9131 : Claus MAYR (Airbus)9132 : Craig MANERS (Rolls Royce)9133 : Michael STOCK (Rolls Royce)9134 : Albrecht Feldsmann (Airbus)9136 : Bernard LAURAS (Airbus)9137 : Juan Ignacio MARTIN (Airbus Military)9138 : Dan FITZSIMMONS (Boeing)9139 : Jesse MANGUAL (Moog)9162 : Dale GORDON (Aerojet)
Current / Future State Mapping
Current State• Independent release
of standards
•Most OEM’s deploy 9100
•Limited supply chain eligible and required to deploy 9100
•Standards supported for deployment presentations
•Few measures in place
Strategic Focus Project manage future
integrated standard releases Collaborate with Strategy
Streams IAQG 5 year strategy - Lead
90% certification Ensure standards are current
and relevant Develop and maintain
document support materials and improve communications
Engage in ISO activities and obtain liaison voting status
Develop future QMS concepts and measures
Future State• Integrated release of
future standards
• All IAQG member companies use the 9100 series
• All eligible supply chain use 9100 series
• Standard support is easy to use
• Measures drive improvements
6
IAQGStandards
7
Publications
Numbering System International Standards - 91xx
" Are planned for harmonization across all 3 aerospace sectors and are recognized globally
Americas Standards - 90xx" Are published for use by AAQG, may become an 91XX
standard at a later date “AS” Standards - Americas
" Published by Society of Automotive Engineers (SAE) “EN” Standards - Europe
" published in Europe by ASD-STAN “JIS Q” or “SJAC” is the Japan / Asia Equivalent
8
IAQG Document Relationships
Oversight of Certification Scheme9104-1 (organization) 9104-2 (surveillance/certs) 9104-3 (auditors)
Maintenance of stds issued by IA
QG
(IAQ
G 103)
IAQG OWNERS Data TypeDATA
Peop
le
Cap
abili
ty
Stra
tegy
St
ream People Capability documents (PCAP001) & structure (skills matrix)
Best practices
Prod
uct &
Su
pply
Cha
in
Stra
tegy
St
ream
Supply Chain Management Handbook (SCMH)
Sales & Scheduling
Requirement Flow down
Design & Developm’t
Plant, skills &
planning
Manufact. &
Inspection
SupplierMgt.
Control of N/C mat’lC/A & P/A
Order Mgt & logistics
Customer Support
Sourcing selection
BusinessProcesses
1 2 3 4 5 6 7 8 9 10 11
ICO
P C
ertification Scheme9120 (Distributors)
9100 (General)
9110 (Maintenance)9101Audit
Process
Quality Management System
REQ
UIR
EMEN
TSSt
rate
gy S
trea
m
CertificationScheme
QMS Standards
9103Key Char
9102FAI
9107DDA
9114Direct ship
9131N/C Doc
9132Marking
9133Sup.Qual.
9138Stat Prod Ac
9162Self Ver
9115Software
9137AQAP align.
91XXAPQP/PPAP
9
Why have 9100?– High risk products– High cost products
Price estimates (millions)– F35 56-97– 737 74-107– 777 258-297– A380 375– Satellite 290-682– Delta IV 254-300
The 9100 Drivers
What else drives the need for 9100? Tightly controlled industry requirements
– Statutory
– Regulatory
– Customer
Safety is a must!Quality is required!Failure is not an option!
Need for 9100 Series
Law of Gravity
What is the partnership between 9100 and ISO 9001? Goal is for 90% of the supply chain to be 9100 certified It is recognized that lower tier suppliers do not always
need the rigor of 9100 Certification to 9100 can be as a dual certification with
ISO 9001 Having ISO 9001 as the baseline to 9100 helps keep
QMS continuity across the AS&D supply chain
ISO Partnership
Getting More from QMS
How AS&D gets more out of its QMS? Raise stakeholder input and
participation to a higher level
Use a widely accepted and respected baseline standard
Address the questions many CEOs are asking of their QMS, “How to add value, reduce cost, improve quality time delivery”
ISO 9001 versus 9100
9100 has ISO 9001:2008 embedded with added “requirements” that provide for:
Additional focus on customer and applicable statutory and regulatory QMS requirements
Special Requirements/Critical Items Project Management Risk Management Configuration Management Control of Work Transfers Design and Development V&V Testing and Documentation Increased Supplier Oversight and Monitoring Production Process Verification Production Process Change Control Production Equip, Tools and Software Programs Control Post-Delivery Support
Blue Text Indicates additions to 9100:2009 Requirements
24 Standards (existing and in work) - 12 Active Projects– 6 Review Standards in the ballot or
publish phase (9101, 9102, 9104-2, 9114, 9116, 9136)
– 3 Development Standards revisions in development (9100, 9104-3, 9107)
– 4 New Projects New standards in development (9117, 9138, 9139, 91XX)
– 4 Study Standards planning a revision (9110, 9120, 9115, 9137)
– 3 Study Past due for reaffirmation – in work (9132, 9133, 9162)
– 4 Sustain Sustain and maintain
Standards Activity Summary
15
GOAL - Complete the development, ballot and publication process for the 12 active standard projects on schedule
Standards in Review (active ballots)" 9101 “Quality Management Systems Audit Requirements for
Aviation, Space, and Defense Organizations”• Nearing ballot process completion and will be going to publication
" 9114 “Direct Ship Guidance for Aerospace Companies”• Affirmation ballot initiated
" 9116 “Notification of Change”• Ballot results pending
" 9104-2 “Requirements for Oversight of Aerospace Quality Management”
• Ballot is in process, affirmation ballot launched in the AAQG" 9102 “Aerospace First Article Inspection Requirement”
• Ballot has been initiated and the results are pending" 9136 “Root Cause Analysis and Problem Solving”
• Closure date for the IAQG Sector ballot is January 2014
IAQG Standards – Ballot/Publish
16
IAQG standards in Development (revisions) 9100 “Quality Management Systems - Requirements for
Aviation, Space and Defense Organizations”" Comments reviewed and dispositions applied in Montreal
9104-3 “Requirements for Aerospace Auditor Competency and Training Courses”" The plan is for a draft to be ready for ballot early next year
9107 “Direct Delivery Authorization Guidance for Aerospace Companies”" Revision is in work and will have additional focus after 9114 is
complete – Project launch in Montreal
IAQG Standards - Revisions
17
IAQG standards in Development (new) 9117 “Delegated Product Release Verification (DPRV)”
" Planned ballot draft for Montreal postponed to address a couple emergent issues that surfaced in their Montreal meeting
9138 “Statistical Product Acceptance” " Standard number issued and regularly scheduled meetings are
being held via WebEx/Telecon 9139 “Bodies of Knowledge”
" Ballot draft is getting near being ready and the goal is to publish in June 2014
- 91XX “Advance Product Quality Planning” (APQP) / “Production Part Approval Process” (PPAP)" SWG and Council approved in Moscow - First team meeting held
in September
IAQG Standards – New
18
IAQG standards in Study/ Past Due Review 9132 “Data Matrix Quality Requirements for Parts
Marking”" Noncompliant to review requirement – EAQG identified IDR and SDR –
revision needs are being reviewed 9133 “Qualification Procedure for Aerospace Standard
Parts”" Noncompliant to review requirement - Working draft complete and SDRs
are reviewing. 9162 “Aerospace Operator Self-Verification Programs”
" Noncompliant to review requirement – The IDR has completed the project plate, a revision has proposed in Moscow and team formation is in process
IAQG Standards – 5 Year Review
19
IAQG standards in Study for Revision 9110 “Quality Management Systems - Requirements for Aviation
Maintenance Organizations”" Scope of revision being determined based on 9100 changes, IAQG
direction and stakeholder feedback 9120 “Quality Management Systems – Requirements for Aviation,
Space and Defense Distributors”" Scope of revision being determined based on 9100 changes, IAQG
direction and stakeholder feedback 9115 “Quality Management Systems -Requirements for Aviation,
Space and Defense Organizations -Deliverable Software” " Scope of revision being determined based on 9100 changes, IAQG
direction and stakeholder feedback
9137 “Guidance for the Application of AQAP 2110 within a 9100 Quality Management System”
" Scope of revision being determined based on 9100 changes, IAQG direction and stakeholder feedback
IAQG Standards – Study
20
ISO 9001:2015 Revision Status
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Page 22
ISO 9001:2015 Revision Status
Committee Draft (CD) released June 2013US TAG 176 voted no on CD due to amount of comments (over 1000) and overall immaturity
Vote results from all countries expected in early October
The ISO 9001:2015 Team is meeting in Portugal in early November to disposition all comments
We should have a new DIS by the IAQG Brussels meeting
May 2013 CD(Committee Draft)
February 2014 DIS (Draft International Standard)
February 2015 FDIS (Final Draft International Standard)
September 2015 Published IS (International Standard)
201520142013
+ Transition period for certification
ISO 9001 Revision Timeline
HLS & Sub-clauses 1.Scope 2.Normative references 3.Terms and definitions 4.Context of the organization
• Understanding the organization and its context
• Needs and requirements • Scope • Management System
5.Leadership • General • Management commitment • Policy • Roles, responsibility and
authority 6. Planning
• Actions to address risks & opportunities
• Objectives and plans to achieve them
HLS & Sub-clauses 7. Support
• Resources • Competence • Awareness • Communication • Documented information
8. Operation • Operational planning and
control 9. Performance evaluation
• Monitoring, measurement, analysis & evaluation
• Internal audit • Management review
10. Improvement • Non conformity and corrective
action • Continual Improvement
New Clause Structure
ISO High Level Structure (HLS)
24
9100 Series2015 Revision Plan
25
9100 AAQG SDRLockheed Martin
Buddy Cressionnie
9101 IDRMitsubishi Heavy Industries
Masahiro Kawamoto
9100 EAQG SDRZodiac
Brigitte Clamens
9110 IDRAirbus
Agathe Moll
9100 APAQG SDRMitsubishi Heavy Industries
Masahiro Kawamoto
9120 IDRAerojet
Dale Gordon
Inse
rtP
ictu
reH
ere
9100 ScribeIAQG
Wayne Johnson
9137 IDRAirbus Military
Juan Ignacio Martin9115 IDRRaytheon
Ray Wright
Inse
rtP
ictu
reH
ere
Integration of Standards
9100 AAQG RepresentativeUnited Technologies Corporation
Jim Clifford9100 EAQG Representative
European Space Agency
Roberto Ciaschi9100 APAQG Representative
Aviation Industry Corporation (AVIC)
Chen Zhongyuan
9100 AAQG RepresentativeTBD
TBD9100 EAQG Representative
Rolls Royce
Stuart Anthony9100 APAQG Representative
Kawasaki Heavy Industries
Tatsuya Shirai
9100 IDR – Team LeaderBoeing
Alan Daniels
IAQG 9100 Series Team
IAQG 9100 Series Team
26
9100 Series Revision High Level PlanThe 9100 is based on ISO 9001 and is thus affected
by the ISO TC176 revision activitySeveral other IAQG standards are based on the IAQG
9100 standard, and will require revision in parallel with the 9100 standard revision activity
The IAQG 9100-series standards are planned for project completion in early 2016
Revision focus is to fix what is broken and be very cautious in adding any new requirements" Sound reasoning and the benefits are clear
27
9100 Series Revision
9100 Series Revision High Level PlanThe 9100 is based on ISO 9001 and is thus affected
by the ISO TC176 revision activity
Several other IAQG standards are based on the IAQG 9100 standard, and will require revision in parallel with the 9100 standard revision activity
The IAQG 9100-series standards are planned for publication in 2016
9100 Series Revision
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Scope of Revision – IAQG approved May 2012 Documented in the 9100:2015 Design Specification Complete
Utilize Survey and Comments Template feedback Complete
Integrate schedules and publication dates for 9100 Series (9100, 9110, 9120, 9115, 9137) Complete
Incorporate ISO 9001:2015 Revision Text In work
Address Future Concepts from the SWG In work
" Counterfeit parts" Safety Management System" IAQG Expanded Strategy
Fix what is broken and be cautious in the adoption of new requirements - the benefits must be clear to all stakeholders Beginning in 2014
29
9100 Revision Scope
9100 SeriesThe term “9100 Series standards” includes the following IAQG standards:
IAQG 9100 Quality Management Systems –Requirements for Aviation, Space and Defense Organizations
- IAQG Series Baseline Standard" IAQG 9110 Quality Maintenance Systems – Requirements for
Aviation Maintenance Organizations" IAQG 9115 Quality Management Systems - Requirements for
Aviation, Space and Defense Organizations - Deliverable Software
" IAQG 9120 Quality Management Systems – Requirements for Aviation, Space and Defense Distributors
" IAQG 9137 Guidance for the Application of AQAP 2110 within a 9100 Quality Management System30
9100 Series Revision
30
AAQG 9100 Team
EAQG 9100 Team
APAQG 9100 Team
AAQSC Sector
9100 Team
IAQG 9100 Team
EAQG Sector
9100 Team
APAQG Sector
9100 Team
Stakeholder Team
Representatives
Team meets at Sector Meetings to gather Sector inputs and develop Sector positions. Operation managed at Sector Level.
Subset of Sector 9100 Team to represent Sector at Int’l Meetings
Intl 9100 Team collects sector and stakeholder input and writes the revision
31
IAQG/Sector 9100 Team Structure
AAQG Leader - Buddy Cressionnie (Lockheed Martin) [email protected]
Team Members - Jim Clifford (UTC) [email protected] - Dale Gordon (Aerojet) [email protected]
- Kevin Beard (NQA) [email protected]
- Sydney Vianna (DNV) [email protected]
- Anne Moore (Boeing) [email protected] - Eric Jeffries (Bell/Textron) [email protected]
- Gill Helsel (Bell/Textron) [email protected]
- Scott Monroe (Alcoa) [email protected]
- Aaron Troschinetz (SAI) [email protected]
- John Graham (PNAA) [email protected]
- Brian Geer (Lockheed Martin) [email protected]
- Robert Bodemuller (Ball Aerospace) [email protected]
- Dave Leeson (GD) [email protected]
- Helen Kiesel (Goodrich) [email protected]
32
AAQG 9100 Team
Page 33
EAQG Leader Brigitte Clamens (Zodiac)
33
AFNOR France Michel FRANCES AIRBUS France Alain GROSAIRBUS Military Spain Juan Ignacio MARTINAIRBUS Operations Germany Hans-Joachim ZARRATHALENIA AERMACCHI Italy Augusto d’AVOSSAALENIA AERMACCHI Italy Flavio IZZOASTRIUM Germany André LACROIXAUSTRIAN Standards Institute Austria Manfred LESERBAE SYSTEMS UK Peter CRACKNELL BUREAU VERITAS Certification France François DUMESNILDIN Institute for Standardization Germany Detlev BOHLEEADS France Jean-Louis DOULIERYEADS Elbe Flugzeugwerke Gmbh Germany Ralf KLINKMULLER ESA Netherland Roberto CIASCHIEUROCOPTER France Hervé MOURICHOUXEUROCOPTER Germany Andreas SCHWARZFACC AG Austria Hubert KERNGKN AEROSPACE Sweden Martin RESTIN INTERTEK CERTIICATION France Jean DESJARDINSLIEBHERR Aerospace France Karine FEILMBDA France Isabelle GUIVARCHMEGGITT UK Francis GARY ROLLS-ROYCE UK Stuart ANTHONYSAFRAN - Messier Bugatti Dowty France Isabelle VOUGAZ SAFRAN - Turbomeca France Patrick BOUCHERONSONACA Belgium Marc DEPIEREUX
27 - Members 9 - Countries
Representatives of : • Organizations• Certification Bodies• 9100 series standards• Stakeholders
Members working within the IAQG 9100 team
EAQG 9100 Team
APAQG Leader - Masahiro KAWAMOTO (Japan, MHI)
Team Members -Tatsuya SHIRAI (Japan, KHI)- Chen ZHONGYUAN (China, AVIC)- Zhang HAIYUN (China, Boeing Tianjin Composite)- Woochul JUN (Korea, Korean Air)- Leng Koon LEE (Singapore, DSO)- Masayuki KOGUSURI (Japan, IHI)- Jumpei ONO (Japan, MHI)
Note: Each country of APAQG member companies (China, Indonesia, Japan, Korea, Singapore, Taiwan) will assign team members.
34
APAQG 9100 Team
9100 SeriesStakeholder Feedback
35
Stakeholder IAQG Leader 9100 Team LiaisonExternalCertif Bodies /Aero Auditors Tim LEE Masahiro KAWAMOTO9100 Certified Organizations Brian BLOUNT Brian GEERAirline and aviation operators Alain GROS Isabelle VOUGAZDistributors Dale GORDON Dale GORDONDeliverable software orgs Raymond WRIGHT Raymond WRIGHT
InternalIAQG & sector member companies Alan/Buddy/Brigitte/Masa 9100 Leader, Sector LeadersIAQG Strategy Streams/Teams
" Requirements Alan DANIELS Alan DANIELS" People Capability Jesse MANGUAL Stuart ANTHONY" Product & SC Improvement Bernard LAURAS Jim CLIFFORD" Performance Improvement Christian BUCK Buddy CRESSIONNIE " OPMT & Certification Bodies Tim LEE Masahiro KAWAMOTO" Integration Jim CLIFFORD Jim CLIFFORD
IAQG Relationship Growth" MRO orgs Alain GROS Agathe MOLL" Civil Aviation Authorities Ed BAYNE Alan DANIELS" Defense / NATO Mike HAYWARD Juan Ignacio MARTIN " Space Roberto CIASCHI Roberto CIASCHI" Trade Associations (EAQG) Alain BONNARD Brigitte CLAMENS
36
Stakeholders and Liaisons
Determine Methods to Request Stakeholder Input
Stakeholder Contact Method Data Collection ToolExternal Certification Bodies/Aerospace Auditors Email Leader 9100 Revision Survey 9100 Certified Organizations Email Leader 9100 Revision Survey Airline and aviation operators Email Leaders 9100 Revision Survey Distributors Email Leader 9100 Revision Survey Deliverable software organizations Email Leader 9100 Revision Survey
Internal IAQG & sector member companies Email Leaders Comments template IAQG Strategy Streams/Teams
" Requirements Email, Presentation Comments template
" People Capability Email, Presentation Comments template" Product & SC Improvement Email, Presentation Comments template" Performance Improvement Email, Presentation Comments template" OPMT & Certification Bodies Email, Presentation Comments template" Integration Email Leader Comments template
IAQG Relationship Growth" Maintenance, repair, and overhaul Email Leader Comments template" Authorities Email Leader Comments template" Defense / NATO Email Leader Comments template" Space Email Leader Comments template" Trade Associations Email Leader Comments template 37
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Data Mining: 559 Responses Web Survey Demographics
What is your Sector or Geographical Area?
AmericasEurope
What is the size of your organization?
Small <50 employeesMedium 50-500 employeesLarge 501-5000 employeesExtra Large >5000 employees
How does your customer flow down 9100/9110/9120 standard certification re-
quirement for your organization?
MandatoryRec-om-mended
84 Responses that include non-ASD activities
91% rated 9100 series certification to be valuable in
the management of their organization.
39
Data Mining: 559 Responses Web Survey Responses
How valuable is certification to 9100/9110/9120 in the management
of your organization?Extremely ValuableFairly ValuableValuableSomewhat ValuableNo Value
80% viewed receiving ISO 9001 certification was
valuable as part of 9100 series certification.
How valuable is receiving ISO 9001 certification as part of your 9100
series (9100, 9110 and 9120) certi-fication?
Extremely ValuableFairly ValuableValuableSomewhat ValuableNo Value
Over 74% of respondents
believe that 9100 series requirements
has benefits that outweigh the costs.
Need to better communicate
deployment support materials.
49% of those that knew of materials found
them helpful.40
Data Mining: 559 Responses Web Survey Responses
Implementing the 9100/9110/9120:2009 re-quirements has benefits for my organization
that outweight the cost.
YesNo
The 9100/9110/9120 Deployment Support Material located on the IAQG website
(http://www.iaqg.org/) is helpful.
YesNoDid Not Use
Data Mining Input Summary
41
AAQG 67 APAQG 31 EAQG 89 (out of 175) CAAs 21 Defense 1 LinkedIn (users group) 12 MRO (9110 IDR) 14 PSCI Stream 6 Space Forum (IAQG/AAQG) 18 (out of 29) Trade Organizations 2 Web Survey (Question 10) 96
357 Comments (454 Total)
9100 Series Team Meeting ResultsReviewed 9100 Structure Draft (SD)
Initial disposition determined for 454 comments
Determined sub-team activities needed
Updated 9100 schedule and integrated schedule
Developed a plan for the writing team
New Activity
42
9100 Sub-teams
43
Product Safety (Includes Human Factors) (SD) Agathe Moll
Risk Roberto Ciaschi
Preventive Action (use SD) Roberto Ciaschi
Counterfeit Parts (9100) Dale Gordon
Configuration Management (9100) Dale Gordon
Product Realization Planning (9100) Jim Clifford
Post-Delivery Support (SD) Isabelle Vougaz
Necessity for Design Sub-Team to be determined based on design content in DIS
9100 Team focals listed - each sector to have a representative
Due date February 14, 2014 to sectors teams can assess prior to IAQG Brussels
Page 44
9100 Series RevisionMaster Schedule
44
Nagoya10/2012
Moscow05/2013
Montreal10/2013
Preparing
San Antonio05/2012
Ballots reviews and commentsPublications
9100 revisionSTART
For more information, see detailed schedule
ENDTBD
Begin
WritingBallotDraft
Brussels04/2014
TBD10/2014
2014
TBD04/2015
TBD10/2015
2015
TBD04/2016
TBD10/2016
20162012 2013
TBD04/2017
TBD10/2017
2017
Ready for Publication
CoordinationDraft
Plan & Stakeholders feedback
Internal DependenciesStandards & Training as needed for publication- Required for 9100 publication
- 9100 Transition Plan- 9101 Update (as required)- 9100 Training (as required)
External dependenciesISO 9001 publications• CD May 2013 – Begin struct. draft• DIS : Feb. 2014 – Begin writing 9100• FDIS : Feb. 2015 - Begin Coord. Draft• Publish : Sept. 2015 – Prep. Ballot
9110, 9120, 9115, 9137
Series RevisionsRequired for publication
9101 Audit – Revisions (as needed)9104-1, -2, -3 – Revisions (as needed)
Structure
Draft
Working
Draft
Development
Companies certifiedto revised standards
Training Decision
Auditors training (as needed)(OPMT)
Recommended Schedule to satisfy need date
Required for publication
TransitionPeriod
45
Thank you!
Questions