John Lunardi
Commercial Airplanes | Supplier Quality
John Lunardi
Director, BCA Supplier Quality
John Lunardi is the director of Supplier Quality for Boeing
Commercial Airplanes (BCA). Is this role he leads a global team
of quality professionals with responsibility for regional operations
and field support, supplier product verification, airplane program
support, and regulatory affairs. John works directly with BCA's
domestic and global suppliers to ensure product conformance,
system and process compliance, and systemic, continual
improvement.
He has more than 30 years experience in quality-related
leadership positions in a number of quality functions, as well as in
Business and Program Management at Boeing. John has a
bachelor of science degree in Operations Management from
California Polytechnic University, Pomona.
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Supplier Quality Overview
John E. Lunardi
Director – BCA Supplier Quality
Boeing Commercial Airplanes
July 22, 2015
Copyright © 2015 Boeing. All rights reserved.
Boeing Supplier Quality
Evolution and Strategy
1999: AS9100
2001: Combined
Renton & Everett 2002: Mandated
Nadcap
R&I under SQ
2002: Mandated
ICOP
2010: Common
Surveillance Process
2015
Top 13 Things
1990
2015
Early 90s: Inspect
Everything
Upon Receipt
2000: Initiated 2001: ILHE
Instituted
BCA / BDS
Collaboration
2002: Supplier
Code Delegation
Implemented
2008: Utilization
of Verify
2013: Program
Interface
 Focus on the process and early engagement
– Quality ownership earlier in the Value Stream
 Leverage Other Party Oversight
 Drive for Industry standardization
 Collaborate with BDS – one Boeing voice
 Risk based oversight – reward good suppliers
 Laser focus on key drivers for escapes
– Requirements Flowdown and Consumption
– Sub Tier Supplier Quality
– Change Management
– Work Transfers
Copyright © 2015 Boeing. All rights reserved.
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Boeing Quality Strategy
Design and Build Quality
 Lead the BCA culture of excellence
in safety and quality
 Improve the quality system to
enable and ensure process
compliance and product
conformance
Value
Stream
Quality
System
Capable &
In-Control
Robust &
Efficient
Conformance
Compliance
Leadership
Culture
 Drive elimination and prevention of
defects and disruption across the
value stream
BCA Value Stream
Customers
Feedback
Design
Feedback
Supply
Feedback
Build & Deliver
Feedback
Support
Continuously Improving to Win in the Marketplace
Copyright © 2015 Boeing. All rights reserved.
Feedback
Customers
Boeing Supplier Quality
System for Managing Supplier Quality
The Boeing supply chain quality system is founded on a highly structured
“layered approach,” coupled with a closed-loop corrective action system
People
Early SQ
involvement
Improve
suppliers’
quality
performance
Verify
suppliers’
compliance
Proactive
change
management
Systems & Tools
 Quality in product
development
 Quality
Requirements flow
down and review
 Supplier capability
assessments
Copyright © 2015 Boeing. All rights reserved.
 QMS approvals
 First article
inspections
 Source/receiving
inspection
 Onsite assessments
 Performance
monitoring
 Work transfer
management
 Risk based supplier
surveillance
 Change quality
Management
 Quality Improvement
Performance plans
 Closed loop corrective
action
Boeing Supplier Quality
Supply Chain Focus Areas
Requirements Flowdown
and Consumption
Sub Tier Supplier Quality
Management
Change Quality
Management
Work Transfer
Management
Copyright © 2015 Boeing. All rights reserved.
Boeing Supplier Quality
Top 13 Things You Can Do To Eliminate Escapes
Strong internal process
for requirement
consumption
Mistake proof operations and products
Risk-based approach to
Change Management
“FOD protection” and “Clean as you go”
Tool Control and Preventative
Maintenance
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Conduct FAIs against defined
engineering
Top 13 Things You Can Do To Eliminate Escapes
1. Ensure a strong internal process for requirements consumption
2. Ensure a proactive, risk-based approach to change management
3. Conduct thorough contract reviews with your suppliers to ensure they understand
requirements that are flowed to them
4. Verify processes are in place to ensure work coming from special processors is to the
correct specification and that the processors are in good standing
5. Ensure that any products with customer directed planning are clearly identified so
that changes are not made without customer approval
6. Ensure FAIs are conducted against the defined engineering – not planning!
7. Ensure your process for identifying delta FAIs for any change affecting form, fit or
function is effective
8. Require your suppliers and their sub-tiers to formally notify you of Work Transfers
9. Employ a robust, proactive process for tool control and preventative maintenance
10. Relentlessly pursue standard work - “mistake proof” your operations and products
11. Incorporate both “FOD protection” and a “clean as you go” approach to FOD
12. Ensure strong quality controls over any Operator Verification program
13. Ensure new employees, or employees doing new work, receive the training needed to
perform work flawlessly – the first time
Copyright © 2015 Boeing. All rights reserved.
Summary
 Meeting our commitments is extremely
important to our customers
 In service airplane quality is a top priority for
Boeing
 Both are the ultimate measure of product
quality
 This quality includes design, supplier, build,
delivery and component quality elements
 All of these elements are critical to
protecting out Production System and
preventing in service airplane issues
Quality is a Team Sport !
Copyright © 2015 Boeing. All rights reserved.
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Copyright © 2015 Boeing. All rights reserved.
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