An Aeronautics Supplier’s viewpoint
INTERTECHNIQUE
INTERTECHNIQUE
within
the quality aerospace environment
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 0.1
Summary
Intertechnique Company brief presentation
Quality system requirements
• By Official Authorities
• By Customers
• Types of scoring
Audits
• By Customers and Official Authorities
• Internal audits (quality system, product audits)
Other fields
• Quality questionnaires and surveys
• Quality tools
• Accompanying documents
Conclusion
I.A.Q.G., 26th-29th June 2001 in Berlin
INTERTECHNIQUE
G. Dion/IAQG - 11/06/01 – 0.2
INTERTECHNIQUE
Presentation
of
Intertechnique
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.1
ZODIAC Group :
Presentation of Intertechnique
AIRCRAFT SYSTEMS
Fuel systems, oxygen systems,
hydraulic systems.
Electrical systems.
Systems management.
Lighting, flight deck controls and
displays.
5 business segments
AERO SAFETY SYSTEMS
AIRLINE EQUIPMENT
Emergency evacuation systems.
Passenger seats.
Cabine equipment
(trash-compactors systems,
galleys).
TECHNOLOGY
Deceleration systems.
De-icing cells systems.
MARINE – LEISURE
Marine.
Telemetry.
Computer-Aided
Telephony.
Swimming
pools.
Leisure.
Airbags.
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.2
Presentation of Intertechnique
ZODIAC in 2000
Sales breakdown
Aircraft systems
27 %
Airline equipment
25 %
Aero safety systems
15 %
Derived technologies
9%
24 %
Marine – Leisure
Financial highlights
Zodiac Group Manpower
INTERTECHNIQUE
1 400 M$
9 615 people
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.3
Presentation of Intertechnique
Presentation of Intertechnique
INTERTECHNIQUE
Core Businesses
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.4
Presentation of Intertechnique
Fuel Systems
On ground refuelling
equipment and systems
Formula I race cars
refuelling systems
Systèmes de gestion de
carburant
In-flight refuelling
equipment and
systems
On board fuel circulation
systems
In-flight refuelling
pods
Man-machine
interfaces
Couplings and control
equipment for aircraft-fuelling
systems
indicators,
control units and
panels
Fuel boost and
transfer pumps,
fuel jet pumps
Equipment for fuel, air
and hydraulic circuits :
Refuelling ports,
valves . . .
Refuelling units
Aircraft Fuel System Test Bench
Locations
Intertechnique at Plaisir and Roche-La-Molière - (France)
IDC Aerospace at Milwaukee (Wisconsin, USA)
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.5
Presentation of Intertechnique
Systems Monitoring and Management
Fuel management systems
Air management systems
Gauging
Bleed air monitoring
Hydraulic systems
Level sensing
Air temperature control
Circuit breakers
Flowmetering
Cabin pressure control
Window heat controllers
Monitoring and control
Monitoring and
Measurement sensors
level sensing :
thermistors, float
Flowmeters
control
Man-machine
interfaces
Actuators
electrovalves
ram air door actuators
computers
Indicators,
control units and
panels
Location
Intertechnique at Plaisir
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.6
Presentation of Intertechnique
Oxygen and Life Support
ERGONOMICS, PHYSIOLOGY
Respiratory protection for
pilots, passengers and
crew members
Storage, regulation and
oxygen instrumentation
Pilot protection
(accelerations, hypoxia,
NBC, noise ...)
quick donning
masks
Liquid and gaseous
oxygen tanks
anti-smoke protective
breathing hood
Regulators
Passenger oxygen
drop out module
anti-g Valves
NBC hood
Location
Intertechnique at Plaisir
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.7
Presentation of Intertechnique
General information
Locations
PLAISIR (France)
ROCHE-LA-MOLIERE
Activities
Fuel systems
(France)
INTERTECHNIQUE (Aerospace) Ltd (Great Britain)
Systems management
IDC Aerospace (Milwaukee, Wisconsin, USA)
Fuel, air, hydraulics,
electrical distribution, optronics
IN-EROS (Fullerton, California, USA)
IN-ASIA (Hong Kong, China)
Oxygen and life support
Manpower : 890 people
Turnover : 1 100 MF (150 M$)
Chairman and CEO : E. MARCHEGAY
Deputy CEO : J.P. BRILLANT
References
Airbus family, Agusta, Alenia, ATR, Bell, Boeing,
Bombardier Canadair, Casa, Dornier, Eurocopter,
Falcon, Gulfstream, Jetstream, Mirage, Rafale, Saab,
Sikorsky.
Quality Vice President : Guy DION
Department Vice-Presidents : J.F. HIGOUNET
J.P. LIBIS
J.M. MATHEY
Marketing and sales, Vice-President : M. KNAFO
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 1.8
INTERTECHNIQUE
Quality System
requirements
Acronyms
Certifications timetable
From Official Authorities
From Customers
Types of scoring
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.
Quality system requirements
Acronyms
AECMA-EASE
(European Aerospace Supplier
Evaluation)
ð Association affiliated with AECMA
(European Association of Aerospace
Industries),
composed of members from 5 "Regions" : North
(Denmark, Finland, Norway, Sweden), East (Germany,
The Netherlands), South (Italy, Spain, Portugal), Centre
(Belgium, France), West (United Kingdom, Ireland)
BVQI
(Bureau Veritas Quality International)
ð Certification body.
ð Chinese civil aviation authority.
CAA
ð French military official authority.
DGA
(Direction Générale de l'Armement)
DGAC / GSAC
(Direction Générale de l'Aviation Civile / ð French civil official authority.
Groupement pour la Sécurité Aviation
Civile)
FAA
(Federal Aviation Administration)
ð US official authority.
JAA
(Joint Aviation Authorities)
ð European official authority.
QUALIFAS
(Qualité des Approvisionnements pour
les Industries Françaises
Aéronautiques et Spatiales)
ð Central Region of AECMA-EASE.
TCCA
(Transport Canada Civil Aviation)
ð Canadian civil official authority.
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.0
Quality system requirements
Certifications timetable
Certification
Bodies
BVQI
ISO 9001
AQAP-110
BVQI
ISO 9001
(issue 2000)
Plaisir & RLM
Plaisir & RLM
Customers
QUALIFAS
QUALIFAS
RG Aéro 000 83 RG Aéro 000 83
RLM*
Plaisir
Military
Official
AECMA-EASE
EN 9000-1
AECMA-EASE
EN 9100
Plaisir & RLM
Plaisir & RLM
Authorities
DGA
AQAP-110
Plaisir & RLM
Civil
DGAC
JAR 145
FAA
FAR 145
Repair Station
Repair Station
1993
1994
1995
Official Authorities
1996
DGAC
JAR 21
CAA
CCAR 145
Production
Certification
Repair Station
Certification
1997
1998
1999
2000
2001
2002
(*) RLM = Intertechnique Roche-la-Molière site
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.1
Quality requirements from Official Authorities
Company Quality Certifications (by
Quality System Quality System Civil Equipment
All activities
Military activities
Production
BVQI
ISO
ISO9001
9001
n° 62642
n° 62642
of 12/1999
of 12/1999
(Expiry : 12/2002)
(Expiry : 12/2002)
Quality Manual
& Procedures
• Audits performed
every 6 months
by BVQI
Renewal
every 3 years
DGA/BVQI
AQAP
110
AQAP
110
n° 62642
n° 62642
of 12/1999
of 12/1999
(Expiry : 12/2002)
(Expiry : 12/2002)
Quality Manual
& Procedures
• Audits performed
every 6 months
by BVQI
Renewal
every 3 years
INTERTECHNIQUE
JAA/DGAC
JAR
JAR21
21
n° F.G.005
n° F.G.005
of 12/1997
of 12/1997
(Expiry : 12/2001)
(Expiry : 12/2001)
Production
Organization
Exposition (POE)
& Procedures
• Audits performed
by GSAC
(6 per year)
Renewal
every 2 years
Official Authorities or Certification Bodies)
Civil Equipment - Maintenance
JAA/DGAC
FAA
(Europe)
(USA)
JAR
145
JAR
145
n° F060
n° F060
of 12/1993
of 12/1993
(Expiry : 12/2001)
(Expiry : 12/2001)
Maintenance
Organization
Exposition
(MOE)
• Annual audit
performed by GSAC
in Plaisir, Orly &
Roche-la-Molière
Renewal
every 2 years
FAR
FAR145
145
n° I6QY965J
n° I6QY965J
(Plaisir)
(Plaisir)
n° I4QY966J
n° I4QY966J
(Roche-la-Molière)
(Roche-la-Molière)
of 07/1995
of 07/1995
(Expiry : 07/2001)
(Expiry : 07/2001)
MOE
+ US
supplement
• Annual audit
performed by FAA
in Plaisir &
Roche-la-Molière
Renewal
every year
TCCA (Canada)
CAA (China)
Recognition of
Recognition of
JAR
JAR145
145
n° TCAC 897-30
n° TCAC 897-30
of 12/1997
of 12/1997
(Expiry : 02/2002)
(Expiry : 02/2002)
CCAR
145
CCAR
145
n° F.3516
n° F.3516
de 07/1998
de 07/1998
(Expiry : 12/2001)
(Expiry : 12/2001)
MOE
+ Canadian &
Chinese
supplements
• Annual self-evaluation
report to be provided
to Chinese Authorities
Renewal :
Canada : every 2 years
China : every 3 years
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.2.1
Quality requirements from Official Authorities
Company Quality Certifications
(by Official Authorities or Certification Bodies)
Military Aviation Authorities : Requirements based on ISO 9001 J
Civil Aviation Authorities : Specific requirements L
JAR 21 Production certification :
Mutual recognition from FAA and DGAC J
Product certifications : JTSO, TSO J
Maintenance certification :
FAA / DGAC : turnover FAR145 J
(FAR 145 survey by DGAC)
CAA (China) and TCCA (Canada) certifications (audits and supplemental costs) L
Certification Body (BVQI)
Today : ISO 9001 & AQAP-110 certifications
Next future : AS/EN 9100 assessment ?
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.2.2
Quality requirements from Customers
Customers’ audits, results and approvals
AUDIT FIELD
CUSTOMER
QUALIFAS
AECMA-EASE
BOEING
QUALITY
AIRBUS UK
MAINTENANCE
• EN 9000-1 *
• D1-9000 rev. A *
• EFQM model
Result
Comments
19,2 / 20
New standard
EN 9100 *
7,8 / 10
New standard
BQMS (AS 9100) *
"Silver" level
• BAe/AG/QC/SC1 *
No scoring
BOMBARDIER
CANADAIR
• QD4.6-40 *
No scoring
LIEBHERRAEROSPACE
• LTS-AQ-INS-06-0032 *
18,9 / 20
SAAB
• 80-V-10.1E
89 / 100
GULFSTREAM
• SQAR 0001
No scoring
SYSTEM
AUDITS
Standard
AIRBUS INDUSTRIE
• EN-9110 *
New : AUK/SA/001-3 *
New : LTS-AQINS-06-0276 *
16,4/20
QUALITY
SYSTEM
FEDEX, DHL, SAS
• CASE (North America)
No scoring
* : documents based on the ISO 9001 standard
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.3.1
Quality requirements from Customers
Customers’ audits, results and approvals
Quality System : Harmonized requirements J
in France : through QUALIFAS
in Europe : through AECMA-EASE
At the international level : through IAQG
ð RG.Aéro 000 83 in 1994
ð EN 9000-1 in Feb. 1999
ð AS/EN 9100 in Feb. 2001
Maintenance activities : Requirements to be harmonized L
EN 9110 (every 3 years) (applicable in Europe since 2001)
CASE (every 2 years)
Scoring : Quality System scorings to be harmonized L
Several quality system scoring methods (6 for Intertechnique)
Scoring is an incentive element for improvement : it enables to rate the
progress achieved
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.3.2
Types of Scoring
Several levels of scoring
with various calculation methods
Quality System
Examples :
../20, ../10, ../100, Approved / Not approved
Delivery indicators
New products or repairs
% delivered on time, delayed deliveries, TAT, …
Product quality
Examples :
Rejection rates, QN, R1, R2, IF, IE
Overall scoring
Examples :
E NCC, IP, Q100, quartiles, Gold/Silver/bronze
Expected objectives
A simple calculation method
Indicators to be easily understood by the General Management of companies
Indicators jointly checked by the customer and the supplier
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 2.4
INTERTECHNIQUE
Audits
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 3.1
Quality system audits
performed by Customers / Authorities at Intertechnique’s
Audits
(Products audits not included)
JAR 21
25
23
AQAP 100
19
20
18
15
15
14
13
13
13
12
13
10
12
11
11
8
12 Civil Authorities
11 Customers
10
10
10
8
5
5
BVQI
1
1
0
1993
1994
70
1995
1996
64
1997
51
50
40
2000
2001
55
47
44
Total duration (days)
41
49
44
40
30
1999
Substantial
quantities of audits
61
60
40
1998
0 Military Authorities
35
29
Total quantity of audits
31
20
10
22
25
1999
2000
Audit periodicities
linked to the
certifications
Decrease trend
0
1993
1994
1995
INTERTECHNIQUE
1996
1997
1998
2001
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 3.2
Audits
Quality system audits
performed by Customers / Authorities at Intertechnique’s
(Products audits not included)
Expected objective :
1 quality system audit every 3 years based on the international aerospace
standard, performed either by customer association or certification body
What may allow customers to concentrate their efforts on
other audits :
Logistics (management or customer orders, follow-up of delivery dates; purchase control ;
cost management ; leadtime control, …)
Product audits (FAI, Source Inspections, …)
Process audits (EMPI, EMPF, …)
Design reviews (PDR, CDR, …)
To give a greater importance to internal audits :
Self-assessment : more motivating
Best conditions to set up improvement actions
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 3.3
Audits
Internal quality system audits
140
115
120
92,5
100
85
82,5
100
Total duration (days)
104
80
50
60
Total quantity of audits
37,5
40
46
33
20
15
20
1993
1994
37
34
1997
1998
50
52
1999
2000
0
1995
1996
2001
Quantity of audits : increase trend
Audit duration : shorter (since 1999) :
using check-sheets, (41 audit check-sheets for « system » and « process » audits)
standardising the minutes,
improving the corrective action follow-up
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 3.4
Audits
Internal products audits
Products Audits Quantity
FAI Quantity
250
200
200
150
139
150
41
46
38
100
154
98
50
112
0
1998
1999
2000
FAI (First Article Inspection)
performed at the beginning of serial production or for equipment changes
(the quantity depends on the quantity of new products)
Products audits
Performed on equipment in production
(the quantity depends on the quantity of product families)
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 3.5
INTERTECHNIQUE
Other fields
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.1
Other fields
Answers to customers quality questionnaires and surveys
Answers to quality questionnaires + certificates
Quality certificates only dispatching
106
120
100
70
47
80
60
41
18
40
20
8
10
59
29
0
1998
1999
2000
Necessary standardisation of the answer process
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.2
Other fields
Quality Tools
Tools often recommended by the customers, sometimes mandatory :
Self assessment (EFQM model) E
6 Sigma
Lean Manufacturing
Key characteristics
Fracas
HALT, HASS
Do not require, but promote their implementation
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.3
Accompanying Documents
Other fields
or
F
A
JA
n
O
m
e
orm
F
A
FA
/DC ote
L
B yN
er tion
v
i
l
De clara ance
De mpli
Co
of
in e
h
C
se
INTERTECHNIQUE
3
ag
T
llow
e
Y
ag
T
w
o
l
l
Ye
ic a
f
i
t
r
Ce
03
1
8
te
Lo
ard
C
g
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.4
Quality tools : E.F.Q.M. Model Self-assessment
1999
Reminder - Schedule
BAe
BAe
1998
CIP 4th issue
Nov.
CIP 3rd issue
May
BAe
BAe's review
Filton
Nov. 30
BAe's review
Plaisir
May 6
1997
Internal training
Sept./ Oct.
CIP 2nd issue
Feb.
BAe
CIP 1st issue
Sept.
E
External
ASSESSMENT
Dec. 1-4
On site training
(E.F.Q.M.
General
trainers)
Management
Oct. 16-17
Committee
Sept.
GREEN BOOK (Self(decision)
assessment book)
1st issue : Nov.
Plenary Meeting
June 22
General
Management
Committee July
BAe's review
Filton
Sept. 4
CIP 1st and
2nd drafts
March/April
IMPROVING OURSELVES
PREPARING THE ASSESSMENT
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.5.1
Quality tools : E.F.Q.M. Model Self-assessment
Reminder - Schedule
Self
Assessment
Business Units
Seminaries
2000
Airbus UK
AIRBUS
UK's
review
Plaisir
Aug. 30
Airbus UK
CIP
Assessor
5th
Training
issue
(Brussels)
Feb.
Jan. 1112
CIP
6th
issue
May
AIRBUS UK ’s
review
Plaisir
Mar. 6
CIP
7th
issue
Aug.
Airbus UK
2001
EFQM
Booklet
issue
Oct.
EFQM
Internet
Site
Sept.
D7
Feb.
26-27
Self
Assessment
GM Committee
Seminary
Nov. 20-21
D4
Feb.
6-7
AIRBUS
UK's Review
Filton
May 22
IN-S
March
29-30
D2
March
12-13
IN CIP
issue
April
Revised
Green
Book
issue
May
IN CIP
Review
Nov.
Self
Assessment
Launching
Meeting
Oct
IMPROVING OURSELVES
ORGANIZING SELF ASSESSMENTS
PREPARING SELF ASSESSMENT
IMPROVING OURSELVES
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 4.5.2
INTERTECHNIQUE
Conclusion
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 5.1
Conclusion
Consequences
to the Intertechnique Quality Organization
Quality System staff
0,5 person in 1995 ð Today : 3 people
General documents and Standards
Complexicity of the document management
(Quality Manual, Production Organization Exposition, Maintenance
Organization Exposition, Inspection Procedure Manual, …)
Procedures (Quality Intranet)
High quantity of external audits
Repetition of the same audits (some departments are audited several times
per year)
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 5.2
Conclusion
Our reflections
Quality System
May be unique and can cover 90 % of the requirements from :
Civil Authorities / Military Authorities / Certification Body / Aerospace Customers
ISO 9001 and international standard AS/EN/SJAC 9100 must be fully deployed
Scoring is a progress factor
Simplification
Concensus
Self-assessment is the basis of the continuous improvement
To be promoted, but not be imposed by customers
Focus on products and processes
Any new requirement setting-up should be done only after consultation of the
supply chain
INTERTECHNIQUE
I.A.Q.G., 26th-29th June 2001 in Berlin
G. Dion/IAQG - 11/06/01 – 5.3