1. A Suppliers Viewpoint on AS9100
Wendell Saunders Goodrich- Turbine Fuel Technologies September 25, 2002

2. Goodrich in Top Ranking
Goodrich Aerospace is ranked among the largest
Top 20 Aerospace Companies in the world.
AIRBUS
BOEING
TRW
DASSAULT AVIATION
DAIMLER
LOCKHEED MARTIN
BAe
FINNMECCANICA
AEROSPATIALE
SNECMA
GEC UK
NORTHROP GRUMMAN
HONEYWELL
UNITED TECHNOLOGIES
GENERAL ELECTRIC
THOMSON CSF
BOMBARDIER
RAYTHEON
ROLLS ROYCE
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3. Aerostructures & Aviation Services Engine & Safety Systems
Goodrich Aerospace
Aerostructures & Aviation Services
Landing Systems
Engine & Safety Systems
Electronic Systems
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4. TFT Certifications Regulatory Approvals
FAA PMA Part 21
FAA Part 145, JAR 145 satellites & independents
Designees for both MIDO & FSDO
Military ISO approval
Industry Standard Quality Approvals
ISO 9001:1994 over 6 years, PRI registrar
AS 9000 cert. # 0001, PRI
Pilot site for NADCAP General Quality Systems
Process Approvals
NADCAP – weld, braze/heat treat, NDT
Category I, GE
Proprietary design process source, RR,PWC, Honeywell
Quality Management
Source delegated, self release commercial & military
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5. TFT Products
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6. TFT Customers US Government Aero Engine Primes Commercial Carriers
GE, RR (US & UK), PWC, Honeywell
Commercial Carriers
Airlines & service centers
Stationary Turbine Power Generation
GE, Alstom, Siemens, KHI
Power Generation
Services business speciality coatings
Industrial Products Group
Distributors world wide
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7. Certification Problems
Inherited facilities
Four ISO registrars
Some AS others N/A
Maturity of quality systems
Four unique quality systems
Implement same quality system
Aero, Power Gen, & commercial
Regional FSDO expectations
Satellites, stand alones, delegation of duties
AS at “small sites”
Flow down of ISO/AS to small shops
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8. New Programs demand AS Approvals
The “Ticket to
the Dance”
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9. TFT Quality Strategy Lead don’t follow
It is easier to volunteer than be drafted
Pursue certifications before deadlines
Deadlines cause costs to increase
Anticipate where the industry is going
This conference is a means to that end
Suppliers are key to success
Mom & pop shops are low cost centers, TFT responsible
“Low cost countries” mandate
Flow down of AS compliance is not easy
Primes want deflationary pricing or year over year productivity gains- middle man is TFT
QUALITY STRATEGY
Be recognized as the premier quality supplier in our industry, assuring zero escapes by utilizing our knowledge base, insuring quality is designed AND built into the product
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10. Was AS9100 Needed? ISO fell short of Aero needs
Process, validation, keys, suppliers mgmt.
AS standard does NOT have a significant impact if you were a “Prop. Design supplier”
Switch to process not function was ISO-2000
Must of the Primes already required the elements of the AS standard as part of their quality standards
TFT as a supplier to all “engine Primes” already had to comply to multiple systems
We were routinely & regularly audited for compliance to a customer specific std. Every “engine Prime” had different requirements YES…….. AS9000/9100 was needed
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11. The “Key” to Why AS was needed
“To assure that the customers product requirements are managed by suppliers & sub-tiers, including process & design control of key features to support product conformance, safety & reliability” W.Saunders
The ISO standard fell short of the key elements of process validation, certification, key feature management and supplier control
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12. Engine Primes Expectations
Accept the responsibility “birth to death”
AS9100 assures compliance “birth to death”
“Product Realization” for TFT begins with RFQ
Starting with the idea we are entrusted with all aspects of design to validation, material selection, process control, key features , supplier qualification, inspection, and product production
ISO would not satisfy all of our customers Will AS9100 meet their expectations?
We hope they will……..
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13. Conceptual Design Initial design packaging and layout
Focus on reduction of piece part count, leadtime and cost.
Goal is the elimination of castings and forgings.
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14. Thermal Analysis
Estimation of component temperatures during engine operation.
Prediction of wetted wall surface temperatures in contact with fuel.
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15. Structural Analysis
Conduct linear, non-linear, steady state and transient analyses.
Predicts resultant stresses and life estimations using:
Dynamic Loading
Thermal loading
Static loading
Combined loading
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16. Modal Analysis Predict natural frequency and resultant mode shapes.
Damped harmonic response.
Natural Frequency: f = 528 hz f (damped) = 489 hz
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17. Life Estimation
Turbine Fuel Technologies estimates the component life of fuel metering components by comparing the results of a structural analysis to a temperature dependant database.
If the material or temperature is not available Turbine Fuel Technologies uses a conservative value
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18. Performance Development
Develop nozzle fuel spray to achieve desired ignition and lean-stability characteristics
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19. Actions for AS Compliance
Process owners- tasks & responsibilities -requirements & training CAT 1 req.
How are quality procedures made available - Visual work instructions & on line
Is tooling designed for variable characteristics - issue of SPC management Honeywell keys
In-process inspection before hidden - router review for conformance, NDT issues - Process mapping part of quality plan
Selection of suppliers -ASL based on quality, price & delivery - Full program done for ISO

20. Special Issues of AS9100
How are contract requirements flowed to suppliers FAA ACSEP & ISO std. Req.
Key characteristic control plan from customer - In place for five years- GE, Honeywell, PWC
Design control by agency or customer - timely implementation process - log record eng. changes and actions - Tollgate design model
Use of only customer approved special processes --Design source & MTP system
Right of entry by end customer at suppliers - Part of P.O. document
Delegated source procedure, control of suppliers - Developed system of qualification and mgmt.

21. Special issues AS9100
Marking of regraded material - Regrade not allowed at TFT
Scrap control & disposition - System in place for 10 years FSDO
How to notify customer on NCM material - Clear part of design tollgate on MRB authority
Quality records readily available to customer - CD ROM record retention for personal reasons
Response on service request - system, controls, regulations - Designated functions for Service for ISO
Is sampling inspection used for acceptance - is it valid & appropriate - stop acceptance of defects - Process validation part of quality plan

22. AS9100 continued
Certification test reports for acceptance, type & frequency of lab check, lab reports how often - NADCAP & customer appr. labs selected
First article inspection required, procedure - Switch to AS9102
Insp. & test equip. control, charts, automated, software, plotters (comparator charts) personal gages - ISO plan to control all product acceptance
Is recall planned for inspection & test - ISO plan met AS level
Control of acceptance stamps, media, electronic sign. - Military work mandated procedure
Control of use-as-is NCM, customer approval - Clear part of design tollgate on MRB authority

23. What are our issues today?
Customers are still auditing
NADCAP(3), Cat. 1, ISO, and two customer audits Oct/Nov 2002
Actions
Can we get agreement among all of the Primes?
Issue
Airlines, OE’s and service providers continue to audit for CASE and claim they must do their own audit (10 this year)
Actions
Help….
What can IAQG do to end the madness….
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