AEROSPACE QUALITY MANAGEMENT - INDUSTRY APPROACH Mark P. Allen Chairman Americas Aerospace Quality Group SAE Aerospace Committee G-14 February 14th 2002

AAQG Legitimacy Committee of the Society of Automotive Engineers - designated Committee G14. Operations are under the guidance and rules of SAE committees. A cooperative organization within the aerospace industry in the Americas (including North, Central and South Americas). Processes are established in a set of agreed, documented, operational procedures. Not a legal entity. It is the responsibility of individual companies to implement such agreed upon common procedures.

AAQG Purpose Establish and maintain a dynamic cooperation based on trust between Americas aerospace companies on initiatives to make significant improvements in quality performance and reductions in cost throughout the value stream. Initial focus is to continuously improve the processes used by the supply chain to deliver consistently high quality products, thereby reducing non - value added activities and costs.

AAQG and IAQG Objectives Establish commonality of quality standards and requirements Common aerospace basic quality systems Best practices in aerospace industry Performance metrics Establish process of continuous improvement at suppliers Industry expectations Lean manufacturing Supplier performance metrics Establish methods to share results Audits Inspections Supplier performance Establish implementation plans that bring the initiative to life Obtain regulatory concurrence

AAQG 2002 Goals Document policies and procedures Formalize a charter Initiate migration from system compliance to product conformance More closely align with industry associations & other groups to eliminate redundant activities DoD, Space, AIA….. Continue project initiations and completions Continuing education for the membership

AAQG - Membership Members Goodrich Boeing Company* Rockwell-Collins Bombardier - Canada* Embraer Aircraft - Brazil* ENAER - Chile GE Aircraft Engines* Gulfstream Aerospace Honeywell* HELIBRAS - Brazil Lockheed Martin* LMAASA - Argentina Northrop Grumman* Parker Aerospace * Denotes - IAQG Council Member Rockwell-Collins Rolls-Royce Corp. Raytheon Aircraft Textron* Bell Helicopter Cessna Aircraft United Technologies* Pratt & Whitney Sikorsky Aircraft Hamilton Sundstrand Vought Aircraft Non-Voting Members Suppliers RAB IAAR

AS 9100 Industry Acceptance / Usage The IAQG implementation metrics show that; 46% of members have implemented 9100 internally and to their suppliers 18% of members have implemented 9102, FAI, internally and to their suppliers. 8% of companies have implemented the recently published 9103, Component Proving, internally and to their suppliers. Implementation is gaining momentum and this will increase, particularly when the new Boeing Quality System is reissued. The sector implementation approaches are also making good progress but the benefits from global mutual recognition of Quality System audits is still not quite there yet - we need the global database.

9100 Standard Alignment with ISO 9001:2000 IAQG had the responsibility Aligned aerospace requirements with the new ISO 9001:2000 Incorporated lessons learned - clarified requirements Coordination and resolution was by geographic sectors Americas (AAQG) Europe (EAQG) Asia (SJAC) Goal to publish revision to AS9100 and prEN9100 and any other translated versions - est. June 2001 AS9100A published by SAE in August 2001

9100:2001 Highlights Tokyo, March 2000 Seattle, June 2000 1st Draft - Provided to IAQG Sectors for review Seattle, June 2000 Consolidation of Sector comments September, 2000 - Draft updated to 9001 FDIS Toulouse, November 2000 Continued review and consideration of changes for clarification & “lessons learned” January, 2001 - Draft updated to final ISO 9001:2000 New Orleans, March 2001 Final Review and approval

9100:2001 Highlights (cont.) Intent of aerospace-unique requirements are not changed in new version of 9100 ISO 9001:2000 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 9100:2001 contains 80 aerospace unique requirements and 18 amplifications/notes

ISO 9001:2000 / 9100:2001 Timeline 2000 2001 2002 2003 DEC. 2003 ISO 9001:1994 ISO 9001:2000 9100 : 1999 9100A : 2001 9100B ? 9100A:2001 will include both ISO 9001:1994 and ISO 9001:2000 models until December 2003

Aerospace-Sector Standard Development Timeline August 2001 1995 1996 1997 1998 1999 2000 2001 T/C 20 WG 11 IAQG Munich WG 11 Review Review Formed AS9000 prEN9000-1 Joint US/Euro EN9000-1 AS9000 Initial ARD9000 AS9000 Meeting Issued Released Start prEN9000-1 Philadelphia Paris prEN9100 AS9100 Madrid Tokyo Seattle Toulouse New Orleans AS9100A

Other Party Surveillance (Americas Companies) AAQG is implementing SAE AIR 5359A document AIR 5359A is approved & published AAQG is working directly with Accreditation Bodies to approve CB’s and Auditors 22 CB’s & 110+ auditors submitted by RAB have been Accredited to AS9000 22 CB’s (and 126 auditors) are Accredited to AS9100 at this time. More are expected 126 70+ AEAs and 56 regular auditors

THE AMERICAS Other Party System Standards Council of Canada Registrar Accreditation Bureau INMETRO

Oversight Summary Industry Co-operation on Quality System Requirements A single global 9100 Aerospace standard An agreed International process for procedure creation Sector processes for 2nd or Other party approvals Individual sector plans launched / global plans in work Implementation planned progressively during 2001-2002 Establish a mechanism for data exchange International auditor training and qualifications Communication to Authorities and Stakeholders Industry will Monitor results and maintain momentum

Aerospace Quality System Standards INTERNATIONAL STANDARDS 9100 - Quality System for Aerospace Manufacturers 9110 - Quality System for Aerospace Maintenance Organizations - In work 9120 - Quality System for Aerospace Distributors - In work

Aerospace Quality Standards (cont.) International First Article Inspection Management of Key Characteristics Record Retention Nonconformance Documentation 2D Bar Coding (Draft) Part Qualification Process Americas AS9003 - “Less than” 9100 Production Process Planning Verification (software) Software Quality (Embedded / Product Acceptance) Internal Auditing Requirements Sub-tier Supplier Control Direct Shipments & Electronic Signatures

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

COPIES OF STANDARDS, REPORTS AND CHECKLISTS ARE AVAILABLE FROM SAE WWW.SAE.ORG Society of Automotive Engineers 400 Commonwealth Drive Warrendale, PA 15096-0001

Aerospace Quality Coordination Effort Creation of Separate “SPACE, CIVIL & DEFENSE COMMITTEES” under AIA (incl. all associations) Would meet to address unique needs of each industry segment within the framework of a coordinated Industry process. Would include participation of all affected Industry organizations including FAA, DoD and NASA. AAQG process would remain unchanged AIA Committees would join with the AAQG to integrate strategy and develop the products and tools needed for implementation AAQG responsible for common standards, tools and methods with supplementation for specific sector needs Involve NADCAP Activities with AAQG Special Process issues would be assigned to NADCAP and Quality Systems would be handled through the AAQG

Arrangement of Quality Committees NADCAP CIVIL AVIATION TACTICAL FAA Civil Aviation Quality Committee AIA / GAMA ASA / ARSA OEM’s / PAHs MILITARY DoD Defense Quality Committee NDIA / EIA AIA-SMC AQWG Suppliers AIAA SPACE SPACE Quality Committee NASA

SINGLE VOICE FOR QUALITY IN AEROSPACE INDUSTRY Proposal would Eliminate overlap in Committees and Organizations Reduction in resources and travel costs for participants Eliminate redundant activities Increase in Communications between Groups and Leadership Focus customer and user information in many areas Increase response and decision time for implementation Obtain broader involvement of suppliers, customers and regulators Better coordination / implementation of government / industry initiatives Provide inputs and coordination for Global Quality Issues for the International Aerospace Quality Group

ORGANIZATIONAL BENEFITS TO INDUSTRY Executive Quality Group Clear senior level direction with supporting resources Ability to challenge the status quo Includes representation from Industry Associations Americas Aerospace Quality Group Development of industry-wide (global) processes when appropriate Linkage with international organizations and initiatives through the IAQG Official alignment with an ANSI recognized Standards Development Organization (SAE) Commitment to use products both internally and with suppliers Formal linkage to the supplier community

ORGANIZATIONAL BENEFITS TO INDUSTRY AIA managed business-line unique Committees (Civil, Defense and Space) Involvement of all stakeholders - customers, suppliers and associations "Authorized" linkage to political and government/regulatory organizations Communication with a business-line and across parallel business-lines Linkage to other AIA Councils and Industry Associations

AAQG would perform Integration Function (incl International) INDUSTRY QUALITY POSITIONS / ACTIONS EXECUTIVE QUALITY GROUP AMERICAS AEROSPACE QUALITY GROUP STRATEGY & RESOURCES COMMUNICATIONS VALIDATION NADCAP SPACE CIVIL AVIATION DEFENSE STANDARDS Working Teams Working Teams Working Teams Working Teams

Proposal for New Aerospace Quality Coordination Effort Monday Tuesday Wednesday Thursday Working Teams AMERICAS AEROSPACE QUALITY GROUP EXECUTIVE QUALITY GROUP CIVIL AVIATION Working Teams DEFENSE Working Teams NADCAP EXECUTIVE BOARD MEETING SPACE Working Teams Series of Structured Meetings in the Washington D.C. Area Twice a Year

AAQG Management Approach Aerospace Industry Segment Councils AAQG Commercial Space DoD Council Chairs Mark Allen Andy Brindisi ? ? Standards (PT-S) Dennis Lemon x x x Tools & Techniques (PT-T) Julie Sandrers x x x Implementation (PT-I) D. Buehler x x x Communications (PT-C) C. Adkisson x x x Industry Segment Teams Aerospace Project Teams

Next Meetings June 3-5, Boston, MA Sept. 9-11, Washington, DC

QUESTIONS

Back-up

The International Aerospace Quality Group IAQG Council General Assembly Meetings JAQG SJAC AAQG SAE EAQG AECMA National Trade Associations

IAQG Members Europe Airbus EADS - Airbus/BDLI Rolls-Royce and SBAC EADS (France) ALENIA and AIAD SNECMA EADS - CASA and ATECMA BAE Systems Agusta Aermacchi Eurocopter Dassault Intertechnique/GIFAS MTU Aero engine AECMA Volvo-Aero Americas The Boeing Company GE Aircraft Engines Pratt & Whitney/UTC Rockwell Collins Honeywell Northrop Grumman Cessna - Textron Rolls-Royce Corp. Gulfstream Embraer BF Goodrich Bombardier Bell Helicopter Textron Lockheed Martin Raytheon Vought Aircraft Asia Ishikawajima Harima Heavy Industries Mitsubishi Heavy Industries Kawasaki Heavy Industries Fuji Heavy Industries Shin Mayawa Industries Aviation Industries of China Korea Aerospace Industries Hispano-Suiza Turbomecca Messier-Bugatti Thompson-CSF Sextant

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

Governance Documents 100 Procedure Establishment 101 Project Initiation 102 Committee Membership 103 Maintenance of Standards Charter 104 Committee Meetings SAE Operating Guide SAE Tech Stds Board Governance 2