1. AEROSPACE QUALITY MANAGEMENT SYSTEM 9100
Dale K. Gordon
Past Chairman Americas Aerospace Quality Group
SAE Aerospace Committee G-14
September 25th 2002

2. 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”or “SJAC” is the Japan / Asian Equivalent
Dale K. Gordon

3. Aerospace Quality System Standards
INTERNATIONAL STANDARDS
Quality System for Aerospace Manufacturers
Checksheet for 9100
Quality System for Aerospace Repair Stations
Checksheet for 9110
Quality System for “Pass-Through” Distributors
Checksheet for 9120
Dale K. Gordon

4. Aerospace Quality Standards (cont.)
International Standards
First Article Inspection (9102)
Management of Key Characteristics (9103)
Record Retention (9130)
Nonconformance Documentation (9131)
2D Bar Coding (9132)
Part Qualification Process 9133)
Other Projects
AS “Less than” 9100
Production Process Planning Verification (software)
Software Quality (Embedded / Product Acceptance)
Sampling Plans
Sub-tier Supplier Control
Direct Shipments (ARP 9004)
Electronic Signatures
Digital Data Storage
Dale K. Gordon

5. HISTORY OF 9100

6. Background - Early to mid-1990s
DoD canceled quality system specifications
FAA lacks a definitive description of a quality system
Primes began to flow ISO 9000 series plus unique requirements to suppliers
Suppliers asked industry to standardize
Needed to operate a single quality system
Already adopting ISO 9000 series
Dale K. Gordon

7. Supplier Management and Quality Assurance professionals from:
U.S. Industry Response
Supplier Management and Quality Assurance professionals from:
AlliedSignal Pratt & Whitney
Boeing Rockwell Collins
GE Engines Rolls-Royce Allison
Lockheed Martin Sundstrand
McDonnell Douglas Northrop Grumman
Sponsors
Aviation/Space & Defense Division of
American Society for Quality
SAE Aerospace Council
Dale K. Gordon

8. AAQG Members Agree
“Where aerospace quality is concerned...there is no competitive advantage”
Dale K. Gordon

9. D1-9000 Writing Team Formed DoD AS9000:1997 Inputs ISO-9001 MIL-I NASA
Company
Specific Req’mts
Inputs
ISO-9001
MIL-I
NASA
FAA
MIL-Q
DoD
AS9000:1997
Dale K. Gordon

10. AEROSPACE SUPPLY CHAIN
Tier 1 Vehicle / Airframe / Propulsion Manufacture
Suppliers are NOT Homogenous
Tier 2 Integrators / Source Control/ Software Dev./ Major Assemblies
Tier 3 - Integrators / Source Control / Specialty Electronics / Wiring / Compnts
Tier 4 - Make to Print / Machine Shops / Processors
Special Processes
Tier 5 - Distributors (Fasteners, Raw Materials, Commodities, Adhesives, Special Materials)
Company Specific or
NADCAP
Tier 6 - Raw Materials (Castings, Forgings, Sheet, etc)
Dale K. Gordon

11. Global Quality Standard Activity
Dale K. Gordon

12. ISO TC20 - WG11 ISO Technical Committee 20 - Aircraft & Space Vehicles
Established Working Group 11 (April 1997)
Chartered to develop and publish an international quality system standard based upon ISO 9001 for the aerospace industry
United States (Gene Barker) Convener
Members:
Brazil China France
Germany Japan Mexico
United Kingdom United States
Dale K. Gordon

13. International Quality System Standard Creation 1998
Americas
Standard
European
Standard
ISO 9001
1994
AS9000
prEN
World Aerospace Quality
Standard ; AS/EN/JIS Q 9100
ISO TC 20
WG11
AS9100
EN 9100
Dale K. Gordon

14. Why 9100?
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
Continued from slide 9
Dale K. Gordon

15. AEROSPACE SUPPLY CHAIN
Tier 1 Vehicle / Airframe / Propulsion Manufacture
9100
9110 for Repair Stations
Variation Reduction
FAI
Process Proving
Tier 2 Integrators / Source Control/ Software Dev./ Major Assemblies
9003
Tier 3 - Integrators / Source Control / Specialty Electronics / Wiring / Compnts
Tier 4 - Make to Print / Machine Shops / Processors
9120
Special Processes
Tier 5 - Distributors (Fasteners, Raw Materials, Commodities, Adhesives, Special Materials)
Company Specific or
NADCAP
Tier 6 - Raw Materials (Castings, Forgings, Sheet, etc)
Dale K. Gordon

16. Year 2000 ISO 9000 Revisions
A moving target . . .
Dale K. Gordon

17. 9100 Standard Alignment with ISO 9001:2000
IAQG has 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 est. June 2001
AS9100A published by SAE in August 2001
JIS Q 9100:2001 published by JSA in November 2001
Dale K. Gordon

18. ISO 9001:2000 - Model of a process based quality management system
Continual Improvement of the Quality Management System
CUSTOMER
CUSTOMER
Management
Responsibility
Management
Responsibility
Management
Responsibility
Satisfaction
Product
Realization
input
Product
output
Requirements
Value added activities
Information Flow
Dale K. Gordon

19. 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
Dale K. Gordon

20. ISO 9001:2000 / 9100:2001 Timeline
2000
2001
2002
2003
DEC. 2003
ISO 9001:1994
ISO 9001:2000
9100 : 1999
9100 : 2001
9100:2003 ?
9100A:2001 includes both ISO 9001:1994 and ISO 9001:2000 models until December 2003
Dale K. Gordon

21. FAA Endorsement of AS9100:1999
“The Aircraft Certification Service believes that the effective implementation of AS9100 will enhance an organization’s overall performance, as long as the statement...Other Quality System requirements imposed by the applicable Regulatory Authorities shall be included or referenced in the Quality System documentation is strictly adhered to. Though the FAA does not require the use of the additional elements found in AS9100, it recognizes their benefits to the aviation in increasing an organizations’ efficiency and reducing product and system variance.”
Dale K. Gordon

22. Current USA DoD Position
Proposed Department of Defense (DoD) Adoption of the AS9100: 2001 Quality Management Systems - Aerospace -Requirements (Nov. 2001)
prepared ... DoD adoption notice for the AS 9100:2001 to provide information for document visibility and facilitate document availability to DoD personnel.
International Aerospace Quality Standard AS 9100, 2001 edition, Quality Management Systems--Aerospace Requirements, was adopted on March 1, 2002 for use by the Department of Defense (DoD). The standard specifies additional requirements identified by the aerospace industry specifically for an aerospace quality management system based on ISO 9001:2000 Quality Management Systems Requirements.
Dale K. Gordon

23. Current NASA Position on 9100
NASA issued Adoption notice on April 8th 2002, signed by Dr. Michael Greenfield, Associate Administrator for Mission and Safety Assurance.
This notice makes AS9100A available for use by NASA for procurements for all programs.
Dale K. Gordon

24. SPACE CONSIDERATIONS
ISO TC20 / SC14 and IAQG have on-going project to supplement 9100 w/ special considerations for Space needs
Includes Risk Management & Safety and Mission Assurance emphasis
Use as supplement to 9100
Consideration for full inclusion at next revision of 9100
Other Space considerations with IAQG process / documents to be considered as appropriate
Dale K. Gordon

25. 9100 Checklist
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 Certification Bodies when performing 9100 audits
Scoring feature is currently used by many organizations
Dale K. Gordon

26. 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 FAA / JAA - JAR 145 requirements
Corresponding 9111 checklist has also been developed and published
Harmonized AS9110 is complete - will be published soon (2002)
Dale K. Gordon

27. 9120 Distributor Quality System
EN 9120 developed and implemented in Europe for “pass through” stockists / distributors that handle parts and supplies that are used in aerospace products
Checklist 9121 is also available
Based on 9100, but only applies necessary system requirements.
AS9120 International harmonized standard will be published in 2002
Dale K. Gordon

28. 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

29. Industry Acceptance / Usage
The IAQG implementation metrics show that;
50+% of members have implemented 9100 internally and to their suppliers
20+% 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.
Dale K. Gordon

30. International Aerospace Sector Certification Scheme
Each geographic region or area needs to establish
a system, based on a set of agreed criteria,
which defines how 9100 will be implemented
We will then have agreed and compatible systems
acceptable to all, which allows us to share audit results
and approvals resulting in multiple assessment reduction
and process improvement
Dale K. Gordon

31. What is the Goal of the System?
The goal of the system is for a supplier to receive one
9100 quality systems approval that will be acceptable
to all aerospace OEMs throughout the world.
The key element in this is confidence. The aerospace
OEMs must have confidence in the approvals being
given in other Sectors.
Dale K. Gordon

32. International Requirements for Certification
Single
global standards
9100
Oversight/control
by IAQG
and Sectors
Harmonised systems
of application
Inter-National
Aviation Authority
endorsement
Inter-National
Accreditation
control
International Aerospace
Supplier Quality System
Evaluation/Certification
One audit
accepted by
all Primes
Approved
Cert. Bodies&
Registrars
Active Industry
participation
Approved
Aerospace
Auditors
Data easily
available to all
participants
Global
acceptance by
supplier base
Dale K. Gordon

33. Basic structure of the system International Aerospace Audit Approval Process
IAQG Scheme issued by SAE / AECMA / SJAC
WHAT
requirements
IAQG “oversight”
Americas
Asia
Europe
(equivalent)
(equivalent)
HOW
Americas Scheme
Asia Scheme
Europe Scheme
oversight
oversight
oversight
Accreditation Body
Registrars
Auditors
Assessment
Suppliers
data
Data Base
Accreditation Body
Registrars
Auditors
Assessment
Suppliers
data
Data Base
Accreditation Bodies
Registrars
Auditors
Assessment
Suppliers
data
Data Base
Access Usage
Aerospace Industry Participants

34. Aerospace Supplier Quality System Certification by the IAQG Sectors
IAQG Document 104 Released Jun ‘01
Industry Database Under Construction
Based on Deployment of Sector Processes
AIR5359 / 5493 (Americas)
AECMA - QC (Europe)
SBAC TS157 (UK)
SJAC 9010 / 9011 (Japan)
Dale K. Gordon

35. IAQG Procedure 104 Important Considerations
Includes requirements for AB’s and CRB’s
Includes requirements for auditors
Training requirements are stated
Includes requirements for reporting results of audits
Includes minimum audit times and guidelines
Industry involvement
Must require suppliers to notify OEM’s of status of Registration and any changes thereto
Must report problems with Registrars
Track suppliers vs. Registrars vs performance
Dale K. Gordon

36. 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.
Dale K. Gordon

37. 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 3rd party approvals
Individual sector plans launched / global plans in work
Implementation planned progressively during 2002
Establish a mechanism for data exchange
International auditor training and qualifications
Communication to Authorities and Stakeholders
Industry will Monitor results and maintain momentum
Dale K. Gordon

38. QUESTIONS
Dale K. Gordon