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 Team Leadership Publications Standard Activity ISO Liaison 9100 Series Revision Plan 3 IAQG Strategic Focus Relationship Growth Strategy • • • • • Civil Authorities - Production Space Defense Maintenance, Repair & Overhaul Trade Associations Improvement Strategy • Requirements • People Capability • Product & Supply Chain Improvement • Performance IAQG Operating Management System IAQG Other Party Management Team Integration Team 3 Axes Aligned to Address Challenges 4 IAQG Requirements Team IAQG Leader: Alan DANIELS (Boeing) Mentor: Judy LASLEY (Rolls Royce) AAQG EAQG APAQG Leader: Buddy CRESSIONNIE (Lockheed Martin) Leader: Judy LASLEY (Rolls Royce) Leader: Tatsuya SHIRAI (Kawasaki Heavy Industry) IAQG Document Representatives IAQG Document Representatives 9100 : 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) 9117 : 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) 5 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 Future State Project manage future integrated standard releases • Integrated release of Collaborate with Strategy Streams • All IAQG member 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 standards companies use the 9100 series • All eligible supply chain use 9100 series • Standard support is easy to use • Measures drive improvements 6 IAQG Standards 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 IAQG OWNERS Data Type DATA REQUIREMENTS Strategy Stream Certification Scheme QMS Standards 9101 Audit Process 9110 (Maintenance) 9120 (Distributors) 9103 Key Char 9102 FAI 9107 DDA 9137 9115 91XX AQAP align. Software APQP/PPAP 9114 9131 9138 9133 9162 9132 Direct ship N/C Doc Sup.Qual. Stat Prod Ac Self Ver Marking Supply Chain Management Handbook (SCMH) 1 2 3 4 Sales & Requirement Design & Sourcing Scheduling Flow down Developm’t selection 5 6 7 8 9 10 11 Plant, Order Mgt Manufact. Supplier Control of Customer Business skills & & logistics & N/C mat’l Support Processes Mgt. planning Inspection C/A & P/A People Capability documents (PCAP001) & structure (skills matrix) Best practices Product & People Capability Supply Chain Strategy Strategy Stream Stream Quality Management System Maintenance of stds issued by IAQG (IAQG 103) 9100 (General) ICOP Certification Scheme Oversight of Certification Scheme 9104-1 (organization) 9104-2 (surveillance/certs) 9104-3 (auditors) 9 The 9100 Drivers 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 Need for 9100 Series 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! Law of Gravity ISO Partnership 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 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 Standards Activity Summary 24 Standards (existing and in work) - 12 Active Projects – 6 Review – 3 Development Standards in the ballot or publish phase (9101, 9102, 9104-2, 9114, 9116, 9136) 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 GOAL - Complete the development, ballot and publication process for the 12 active standard projects on schedule 15 IAQG Standards – Ballot/Publish 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 16 IAQG Standards - Revisions 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 17 IAQG Standards – New 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 18 IAQG Standards – 5 Year Review 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 19 IAQG Standards – Study 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 20 ISO 9001:2015 Revision Status 21 ISO 9001:2015 Revision Status Committee Draft (CD) released June 2013 US 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 22 ISO 9001 Revision Timeline 2013 2014 2015 May 2013 CD (Committee Draft) February 2014 DIS (Draft International Standard) February 2015 FDIS (Final Draft International Standard) September 2015 Published IS (International Standard) + Transition period for certification ISO High Level Structure (HLS) New Clause Structure HLS & Sub-clauses 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 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 24 9100 Series 2015 Revision Plan 25 IAQG 9100 Series Team IAQG 9100 Series Team Alan Daniels Wayne Johnson 9100 IDR – Team Leader 9100 Scribe Boeing IAQG Buddy Cressionnie Brigitte Clamens Masahiro Kawamoto 9100 AAQG SDR 9100 EAQG SDR 9100 APAQG SDR Lockheed Martin Zodiac Mitsubishi Heavy Industries Jim Clifford Roberto Ciaschi Chen Zhongyuan 9100 AAQG Representative 9100 EAQG Representative 9100 APAQG Representative United Technologies Corporation European Space Agency Aviation Industry Corporation (AVIC) TBD Stuart Anthony Tatsuya Shirai 9100 AAQG Representative 9100 EAQG Representative 9100 APAQG Representative TBD Rolls Royce Kawasaki Heavy Industries 9120 IDR Aerojet Ray Wright 9115 IDR Raytheon Agathe Moll Masahiro Kawamoto 9110 IDR 9101 IDR Airbus Mitsubishi Heavy Industries Insert Picture Here Dale Gordon Insert Picture Here Integration of Standards Juan Ignacio Martin 9137 IDR Airbus Military 26 9100 Series Revision 9100 Series Revision High Level Plan The 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 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 Plan The 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 28 9100 Revision Scope 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 Series Revision 9100 Series The 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 ̶ IAQG 9115 ̶ IAQG 9120 ̶ IAQG 9137 30 Quality Maintenance Systems – Requirements for Aviation Maintenance Organizations Quality Management Systems - Requirements for Aviation, Space and Defense Organizations Deliverable Software Quality Management Systems – Requirements for Aviation, Space and Defense Distributors Guidance for the Application of AQAP 2110 within a 9100 Quality Management System 30 IAQG/Sector 9100 Team Structure Intl 9100 Team collects sector and stakeholder input and writes the revision Subset of Sector 9100 Team to represent Sector at Int’l Meetings Team meets at Sector Meetings to gather Sector inputs and develop Sector positions. Operation managed at Sector Level. IAQG 9100 Team AAQG 9100 Team AAQSC Sector 9100 Team EAQG 9100 Team EAQG Sector 9100 Team APAQG 9100 Team APAQG Sector 9100 Team 31 AAQG 9100 Team AAQG Leader - Buddy Cressionnie (Lockheed Martin) buddy.cressionnie@lmco.com Team Members - Jim Clifford (UTC) - Dale Gordon (Aerojet) - Kevin Beard (NQA) - Sydney Vianna (DNV) - Anne Moore (Boeing) - Eric Jeffries (Bell/Textron) - Gill Helsel (Bell/Textron) - Scott Monroe (Alcoa) - Aaron Troschinetz (SAI) - John Graham (PNAA) - Brian Geer (Lockheed Martin) - Robert Bodemuller (Ball Aerospace) - Dave Leeson (GD) - Helen Kiesel (Goodrich) james.clifford@pw.utc.com dale.gordon@aerojet.com kbeard@nqa-usa.com sidney.vianna@dnv.com anne.m.moore2@boeing.com EKJefferies@bh.com ghelsel@bh.com Scott.Monroe@alcoa.com aaron.troschinetz@saiglobal.com jagraham@fulcrumassociates.com brian.geer@lmco.com rbodemul@ball.com Dave.Leeson@gdc4s.com Helen.Kiesel@goodrich.com 32 EAQG 9100 Team EAQG Leader Brigitte Clamens (Zodiac) 27 9 - Members - Countries Representatives of : • Organizations • Certification Bodies • 9100 series standards • Stakeholders 33 Members working within AFNOR France Michel FRANCES AIRBUS France Alain GROS AIRBUS Military Spain Juan Ignacio MARTIN AIRBUS Operations Germany Hans-Joachim ZARRATH ALENIA AERMACCHI Italy Augusto d’AVOSSA ALENIA AERMACCHI Italy Flavio IZZO ASTRIUM Germany André LACROIX AUSTRIAN Standards Institute Austria Manfred LESER BAE SYSTEMS UK Peter CRACKNELL BUREAU VERITAS Certification France François DUMESNIL DIN Institute for Standardization Germany Detlev BOHLE EADS France Jean-Louis DOULIERY EADS Elbe Flugzeugwerke Gmbh Germany Ralf KLINKMULLER ESA Netherland Roberto CIASCHI EUROCOPTER France Hervé MOURICHOUX EUROCOPTER Germany Andreas SCHWARZ FACC AG Austria Hubert KERN GKN AEROSPACE Sweden Martin RESTIN INTERTEK CERTIICATION France Jean DESJARDINS LIEBHERR Aerospace France Karine FEIL MBDA France Isabelle GUIVARCH MEGGITT UK Francis GARY ROLLS-ROYCE UK Stuart ANTHONY SAFRAN - Messier Bugatti Dowty France Isabelle VOUGAZ SAFRAN - Turbomeca France Patrick BOUCHERON SONACA Belgium Marc DEPIEREUX 33 APAQG 9100 Team APAQG Leader - Masahiro KAWAMOTO 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) (Japan, MHI) Note: Each country of APAQG member companies (China, Indonesia, Japan, Korea, Singapore, Taiwan) will assign team members. 34 9100 Series Stakeholder Feedback 35 Stakeholders and Liaisons Stakeholder IAQG Leader 9100 Team Liaison External Certif Bodies /Aero Auditors 9100 Certified Organizations Airline and aviation operators Distributors Deliverable software orgs Tim LEE Brian BLOUNT Alain GROS Dale GORDON Raymond WRIGHT Masahiro KAWAMOTO Brian GEER Isabelle VOUGAZ Dale GORDON Raymond WRIGHT Internal IAQG & sector member companies Alan/Buddy/Brigitte/Masa 9100 Leader, Sector Leaders IAQG Strategy Streams/Teams ̶ Requirements ̶ People Capability ̶ Product & SC Improvement ̶ Performance Improvement ̶ OPMT & Certification Bodies ̶ Integration IAQG Relationship Growth ̶ MRO orgs ̶ Civil Aviation Authorities ̶ Defense / NATO ̶ Space ̶ Trade Associations (EAQG) Alan DANIELS Jesse MANGUAL Bernard LAURAS Christian BUCK Tim LEE Jim CLIFFORD Alan DANIELS Stuart ANTHONY Jim CLIFFORD Buddy CRESSIONNIE Masahiro KAWAMOTO Jim CLIFFORD Alain GROS Ed BAYNE Mike HAYWARD Roberto CIASCHI Alain BONNARD Agathe MOLL Alan DANIELS Juan Ignacio MARTIN Roberto CIASCHI Brigitte CLAMENS 36 Determine Methods to Request Stakeholder Input Stakeholder Contact Method Data Collection Tool External Certification Bodies/Aerospace Auditors 9100 Certified Organizations Airline and aviation operators Distributors Deliverable software organizations Email Leader Email Leader Email Leaders Email Leader Email Leader 9100 Revision Survey 9100 Revision Survey 9100 Revision Survey 9100 Revision Survey 9100 Revision Survey Email Leaders Comments template Email, Presentation Email, Presentation Email, Presentation Email, Presentation Email, Presentation Email Leader Comments template Comments template Comments template Comments template Comments template Comments template Email Leader Email Leader Email Leader Email Leader Email Leader Comments template Comments template Comments template Comments template Comments template Internal IAQG & sector member companies IAQG Strategy Streams/Teams ̶ Requirements ̶ People Capability ̶ Product & SC Improvement ̶ Performance Improvement ̶ OPMT & Certification Bodies ̶ Integration IAQG Relationship Growth ̶ Maintenance, repair, and overhaul ̶ Authorities ̶ Defense / NATO ̶ Space ̶ Trade Associations 37 Data Mining: 559 Responses Web Survey Demographics What is your Sector or Geographical Area? Americas Europe 84 Responses that include non-ASD activities What is the size of your organization? How does your customer flow down 9100/9110/9120 standard certification requirement for your organization? Small <50 employees Medium 50-500 employees Large 501-5000 employees Extra Large >5000 employees Mandatory Recommended 38 Data Mining: 559 Responses Web Survey Responses How valuable is certification to 9100/9110/9120 in the management of your organization? Extremely Valuable Fairly Valuable Valuable Somewhat Valuable No Value 80% viewed receiving ISO 9001 certification was valuable as part of 9100 series certification. 91% rated 9100 series certification to be valuable in the management of their organization. How valuable is receiving ISO 9001 certification as part of your 9100 series (9100, 9110 and 9120) certification? Extremely Valuable Fairly Valuable Valuable Somewhat Valuable No Value 39 Data Mining: 559 Responses Web Survey Responses Implementing the 9100/9110/9120:2009 requirements has benefits for my organization that outweight the cost. Yes No Need to better communicate deployment support materials. Over 74% of respondents believe that 9100 series requirements has benefits that outweigh the costs. The 9100/9110/9120 Deployment Support Material located on the IAQG website (http://www.iaqg.org/) is helpful. Yes No 49% of those that knew of materials found them helpful. Did Not Use 40 Data Mining Input Summary AAQG APAQG EAQG CAAs Defense LinkedIn (users group) MRO (9110 IDR) PSCI Stream Space Forum (IAQG/AAQG) Trade Organizations Web Survey (Question 10) 67 31 89 21 1 12 14 6 18 2 96 (out of 175) (out of 29) 357 Comments (454 Total) 41 New Activity 9100 Series Team Meeting Results Reviewed 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 42 9100 Sub-teams 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 43 9100 Series Revision Master Schedule 2012 San Antonio Nagoya 05/2012 10/2012 2013 Moscow 05/2013 9100 revision START 2015 2014 Montreal 10/2013 Structure Draft Brussels 04/2014 TBD 10/2014 TBD 04/2015 2016 TBD 10/2015 Begin Working Coordination Writing Draft Draft TBD TBD 04/2016 10/2016 Ballot Ready for Draft Publication 2017 TBD 04/2017 TBD 10/2017 END TBD Transition Period Plan & Stakeholders feedback Internal Dependencies Standards & Training as needed for publication - Required for 9100 publication - 9100 Transition Plan - 9101 Update (as required) - 9100 Training (as required) External dependencies ISO 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 For more information, see detailed schedule 44 9101 Audit – Revisions (as needed) 9104-1, -2, -3 – Revisions (as needed) 9110, 9120, 9115, 9137 Required for publication Series Revisions Training Decision (OPMT) Development Recommended Schedule to satisfy need date Preparing Ballots reviews and comments Publications Required for publication Auditors training (as needed) Companies certified to revised standards 44 Questions Thank you! 45