AEROSPACE QUALITY

MANAGEMENT SYSTEM
STANDARD AS / EN / JIS Q9100

Dale K. Gordon
Chairman
Americas Aerospace Quality Group
SAE Aerospace Committee G-14
Aerospace Quality Standards
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
 “EN” Standards - Europe
– published in Europe by AECMA
 “JIS Q” is the Japan / Asia Equivalent 20 February 2001 2
Aerospace Quality System
Standards
 INTERNATIONAL STANDARDS
– 9100 - Quality System for Aerospace
Manufacturers
– 9101 - Checksheet for 9100
– 9110 - Quality System for Aerospace Repair
Stations - EAQG
– 9111 - Checksheet for 9110 - EAQG only
– 9120 - Quality System for Distributors - EAQG
– 9121 - Checksheet for 9120 - EAQG

20 February 2001 3
HISTORY - The need to Standardize
Aerospace Quality System Requirements

Inputs
D1-9000

AAQG
Process
AAQG formed in 1995
to Standardize Quality
Requirements for the
Industry

Output AS9000 20 February 2001 4

International Quality System
Standard Creation 1998
Americas European
Standard
ISO 9001 Standard
AS9000 1994 prEN 9000-1

World Aerospace Quality

Standard ; AS/EN/JIS Q 9100

AS9100 ISO TC 20 EN 9100

WG11
20 February 2001 5
Why AS9100?

 To standardize Aerospace quality

expectations on a global level
 To achieve improvements in quality and
reduce costs throughout the value stream
 ISO 9000 model for quality does not capture
regulatory requirements or importance of
safety, reliability or maintainability
 Captures aerospace supplements agreed to
at an international level

20 February 2001 6
Aerospace Quality System 9100
Standard versus ISO 9001

 9100:1999 added 83 additional and

specific requirements to the 20 elements
of ISO 9001
– 11 amplifications of ISO 9001 paragraphs are
also inserted
 Emphasis is placed on Design Control,
Process Control, Purchasing, Inspection &
Testing and Control of Nonconformances
– All areas that have the greatest impact on
safety and reliability for aerospace products

20 February 2001 7
Aerospace Quality System
9100 versus ISO 9001
Aerospace added Requirements (#)
4.1 Management Resp. (2) 4.12 Inspection & Test status (2)
4.2 Quality Systems (7) 4.13 Control of Nonconforming
4.3 Contract Review (3) Product (7)
4.4 Design Control (11) 4.14 Corrective and Preventive
4.5 Document and Data Action (2)
Control (2) 4.15 Handling, storage, package,
4.6 Purchasing (13) preservation and delivery (1)
4.8 Product Identification and 4.16 Control of Quality Records (1)
Traceability (2) 4.17 Internal Quality Audits (2)
4.9 Process Control (13) 4.18 Training (1)
4.10 Inspection and test. (10) 4.20 Statistical Techniques (1)
4.11 Control of Insp., Measure
& Test Equipment (3)
20 February 2001 8
ISO 9001:2000 QUALITY
STANDARD REVISION IMPACT
 Released in US, EUROPE & JAPAN 1999
• International Writing Team reconvened March 2000 to
begin work on ISO 9000:2000 incorporation
• Work is almost complete, planned release for standard
based on ISO 9000:2000 would be mid 2001
• 9100:1999 & 9100:2001 would co-exist until Nov. 2003
2000 2001 2002 2003
DEC. 2003
ISO 9001:1994

ISO 9001:2000

9100 : 1999

9100 : 2001

20 February 2001 9
ISO 9001:2000 QUALITY
STANDARD REVISION IMPACT

 Aerospace unique requirements

are not changed in new version of
9100
– ISO 9000 revision now has requirements
desired by industry, eliminating some
requirements from 9100:1999 version
– Some requirements from ISO 9001:1994 are
desired by industry and were added back to
9100:2001 version
– 9100:2000 contains 80 aerospace unique
requirements and 18 amplifications
20 February 2001 10
9100 Checklist - 9101

 IAQG developed 9101 Common Checklist

to be used by industry to cover all ISO
9001 & 9100 elements - allows industry to
share audit information
 Must be used by Registrars when
performing 9100 audits
 Optional scoring feature
 Purchase of 1 copy from SAE
will give rights to make
unlimited copies for each
site that purchases 20 February 2001 11
9110 Repair Station Quality
System

 EN 9110 developed and implemented in

Europe for facilities that perform
maintenance and repairs of aircraft and
aircraft products
– Based on 9100 requirements and JAA - JAR
145 requirements
• Corresponding 9111 checklist
has also been developed and
published
•International harmonized
version for is being worked
20 February 2001 12
9120 Distributor Quality System

 EN 9120 developed and implemented in

Europe for “pass through” distributors that
broker or distribute parts and supplies that
are used in aerospace products
– Checklist 9121 is also available
in Europe
– Based on 9100, but only applies
necessary system requirements.
– Americas already has several
distributor standards (ASA 100, AS7103)
– International harmonized standard is being
worked 20 February 2001 13
 Industry Leaders are Listening
 Agreed to improve the overall approach to quality
 Major Aerospace Companies have agreed upon Quality
Management System approval approaches
 A key objective is to reduce the number of audits
 There are significant benefits to the Aerospace Industry
 Working to develop our International processes to
incorporate the new approach
 International approach is based on a single agreed
standard, harmonization of system application and shared
information
 Basic structure of the system
International Aerospace 3rd Party Accreditation

IAQG Scheme issued by SAE/AECMA/SJAC

requirements IAQG “oversight” WHAT

Americas Asia Europe

(equivalent) (equivalent)
Americas Scheme Asia Scheme Europe Scheme HOW
oversight oversight oversight
Accreditation Body Accreditation Body Accreditation Bodies
Registrars Registrars Registrars
Auditors Auditors Auditors
Assessment Assessment Assessment
Suppliers Suppliers Suppliers
data data data
Data Base Data Base Data Base

Access Usage

Aerospace Industry Participants

 Process plan for
development/implementation
Describe Get Communicate Implement
the system acceptance the system the system

ISSUE DOCUMENTS

•document sector schemes •obtain sector/IAQG •to Accreditation Bodies •Establish IAQG control
•to Registrars/Certification mechanism
•define elements acceptance
Bodies •establish Sector control
•compare regional schemes •advise authorities
mechanism
•analyse gaps •obtain Accreditation •to the Regulatory
•approve ‘a’ registrar and
•establish equivalence + bodies agreement (IAF) Authorities
‘an’ auditor
harmonisation •Establish a single IAQG •to OEM’s & Trade
•install register(s) of Registrars
•amend Sector schemes procedure Associations and Aerospace auditors
•document international •Final update Sector •to suppliers •set up data exchange
scheme schemes •to the International •run the system
community •monitor and maintain
progress

September 2000 December 2000 1st Q 2001 2nd Q 2001

 Audits and Approvals
Can you imagine a
What a sad place that
world without audits would be

And what would we

do with all that spare
time We could focus on
other things

IMPROVEMENT Like product quality and

project specific requirements
9100 Implementation

 Most IAQG Companies are pursuing phased in

approach to 9100 most have agreed to put on
purchase contract by end of 2001
– Many are targeting specific type of Suppliers for application
 Some Companies will accept only 2nd Party
Approvals
– Some will accept 2nd Party Shared Approvals
 Some Companies will accept 3rd Party Approvals
– Some Accept ISO 9001 Certification with 2nd Party audits of
9100 or elements
– Some are using 9100 approval as a means for Risk Reduction
for 2nd Party Audits
 FAA has issued Order 8120.12 use of “Other
Parties” 20 February 2001 18
Certification / Registration

 “Other Party” Plans being developed for

Certification processes
– SBAC procedure TS157 for United Kingdom
– SAE AIR5359A for Registrar approval for use by AAQG
member companies
• AIR5493 - Auditor training requirements
– AAQG / EAQG / JAQG to prepare and present procedures
for cross evaluation by others (for international use)
 2nd Party shared process
– AECMA - EASE is being used in EUROPE
– Expanded AECMA - EASE being consider for worldwide
use
20 February 2001 19
AIR5359A
Important Considerations
 Includes requirements for OEM’s to share audits
 Includes requirements for auditors
– Training requirements are in AIR5493
 Includes requirements for reporting results of
audits
 Includes minimum audit times and guidelines
 Para 9.8 Industry involvement
– Must require suppliers to notify OEM’s of status of
Registration and any changes thereto
– Must report problems with Registrars
– Should track suppliers vs. Registrars vs
performance
20 February 2001 20
AS9100 Implementation
(Americas Companies)
 2nd Party - Customer Shared Audits

– SAE AIR5359A has sharing plan built-in

– Customer can ask if Supplier wishes to participate
– Auditors must meet requirements in AIR 5359A
– AS9101 Checklist and AIR5359A report must be
used and results left with the Supplier
– Supplier is then free to offer a copy of results to
any other customer
– Results may be used in-lieu of an audit or to
reduce the amount and intensity of an audit
20 February 2001 21
AS9100 Implementation
(Americas Companies)
 Controlled “Other” Party Plan
– AAQG is implementing SAE AIR 5359A document
– AIR 5359A is approved & awaiting publication
– AAQG is working directly with Accreditation
Bodies to approve Registrars and Auditors
– 21 Registrars (150 auditors) submitted by RAB
have been Accredited to AS9000
– 2 Registrars (and 14 auditors) are Accredited to
AS9100 at this time. More are expected soon
– Japan is implementing a similar system to AIR
5359A
– Europe is planning a variation on the same theme
– UK has implemented a compatible scheme
20 February 2001 22
9100 Registration
Attributes
 Salient Points about Registration
– OEM’s are not absolving themselves of any
responsibilities with respect to the supply chain /
products
– Registration increases the level of surveillance by
covering suppliers that the OEM’s do not cover directly.
– Provides for consistent application of requirements
throughout the supply chain (9100).
– Provides for active industry participation and control.
– Provides for data sharing amongst primes and
benchmarks the industry in terms of Quality System
compliance.
– Supplements OEM’s own surveillance process and
allows for more focused process and products audits.
Single Global Procedure

 Based on SAE AIR 5359A

 Embraces all of the key criteria
 Utilizes generic acronym 9100
 It is a 2nd / Other party scheme
 Includes Registrars and Certification Bodies
 Sector Management Structure (SMS)
 Minimum summary data
 Contains minor sector variants
 The document has sub-team agreement

20 February 2001 24
RGM/TS/10073
Tomorrow’s world - on our way

Single
Oversight/control global standards Harmonised systems
by IAQG AS/EN9100 of application
and Sectors
Inter-National
Inter-National
Aviation Authority
Accreditation
endorsement
control

International Aerospace
One audit Supplier Quality System Approved
accepted by Evaluation/Certification Cert. Bodies&
all Primes Registrars

Active Industry Approved

participation Aerospace
Data easily Global Auditors
available to all acceptance by
participants supplier base
 Summary
 A single 9100 Aerospace standard
 An agreed single International procedure of application
 Sector scheme procedures harmonised and complete
 Individual sector launch plans confirmed
 Implementation planned progressively during 2001
 Establish a mechanism for data exchange
 International auditor training and qualifications
 Communication to Authorities and Registrars continues
 No major barriers to implementation
 Team will co-ordinate implementation programs
 Monitor and maintain progress
COPIES OF STANDARDS, REPORTS
AND CHECKLISTS ARE AVAILABLE
FROM SAE

WWW.SAE.ORG
Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096-0001
QUESTIONS

20 February 2001 28