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Digital Product DefinitionA Summary for Aerospace Auditors
Ralph Gamble
The Boeing Company
RMC Workshop Long Beach, 16 – 17 July 2014
Copyright © 2009 Boeing. All rights reserved.
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Introduction
Digital Product Definition, or DPD, is a function of a quality
system that is in constant change according to revised
international standards, technologies and methods. Suppliers
must annually review their digital processes and procedures to
assure there is synchronization with customers that is reflected
in their quality system.
RMC Workshop Long Beach, 16 – 17 July 2014
Copyright © 2009 Boeing. All rights reserved.
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AS9100 – First Article Inspection
A validation of DPD Processes
7.5.1.1 Production Process Verification
The organization shall use a representative item from the first production run of a
new part or assembly to verify that the production processes, production
documentation and tooling are capable of producing parts and assemblies that
meet requirements. This process shall be repeated when changes occur that
invalidate the original results (e.g., engineering changes, manufacturing process
changes, tooling changes).
NOTE This activity is often referred to as First Article Inspection (FAI).
RMC Workshop Long Beach, 16 – 17 July 2014
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How One Company Responds to AS9100:
D6-51991 – QUALITY ASSURANCE STANDARD
FOR DPD AT BOEING SUPPLIERS
Be DPD Aware
D6-51991 has 11 sections responding to AS9100 when building parts
and assemblies for Boeing. This presentation highlights AS9100
non-conforming activities found by the FAA during site audits of Boeing
suppliers and summarized in a DPD Brochure available today.
RMC Workshop Long Beach, 16 – 17 July 2014
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WHAT TO LOOK OUT FOR
RMC Workshop Long Beach, 16 – 17 July 2014
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DOCUMENTED PROCESSES
Is my process up to date, reflect current practices, map to and
included in my AS9100 documentation?
1. Digital Product Definition QA Procedures and Documented Processes
2. Configuration Management and Media Security
3. Product Acceptance Software
4. Internal Quality Audits
5. Problem Reporting and Corrective Action
6. Procurement Control
7. Control of Measurement Equipment
8. Inspection Media
9. Data Exchange Methods
10. Tooling
11. Training and Process Performer
RMC Workshop Long Beach, 16 – 17 July 2014
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NOTIFICATION OF DPD CHANGES
Do I notify the Customer when my CAD, CAM or CAI software or
hardware is changed?
Expectation:
Provide Customer Supplier Quality 30 day notification to
synchronize with Customer CAD platform
Provide Notification of changes to Coordinate Measurement
Systems (CMS) software or hardware. (new Laser Tracker,
Articulating Arm, Scanner, Spatial Analyzer, PCDMIS, etc.
RMC Workshop Long Beach, 16 – 17 July 2014
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CONFIGURATION MANAGEMENT AND
MEDIA SECURITY
Are we maintaining configuration control, change control and
trace-ability of derivative data?
Examples
1. NC Programs – Must be revision controlled and associated to FAI or
Delta FAI at any revision change.
2. Manufacturing Planning
3. Measurement Planning
4. Screen Captures
5. Procedures
6. Model Conversions from V4 to V5
7. Measurement Reports
8. Special Tooling
RMC Workshop Long Beach, 16 – 17 July 2014
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CAD SYSTEM
Is there a CAD system synchronization requirement?
•For Boeing, an Engineering Distribution Group provides only Native CATIA V4 –
V5. If V5 type design occurred in a later version of CATIA, models cannot be
opened or used.
•V4 models will require saving as step or iges and translations must be verified.
•If converted to V5, models must be verified to the authority 2D Drawing and any
authoritative 3D geometry.
RMC Workshop Long Beach, 16 – 17 July 2014
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CAD SYSTEM
If I have to convert from CATIA V4.model to V5.CATpart, do I
have adequate procedures and verification steps in place to
insure a successful, complete and accurate translation?
•Has REFERENCE ONLY information been identified?
•Has the resultant model be compared to authoritative drawing and 3D data?
•Has the resultant model been configured and has trace-ability?
RMC Workshop Long Beach, 16 – 17 July 2014
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PRODUCT ACCEPTANCE SOFTWARE
Has my CMS (Coordinate Measurement System) software been validated as required?
AS9100 - PRODUCT ACCEPTANCE SOFTWARE (PAS)
When used in the monitoring and measurement of specified requirements, the ability of
computer software to satisfy the intended application shall be confirmed. This shall be
undertaken prior to initial use and reconfirmed as necessary.
NOTE Confirmation of the ability of computer software to satisfy the intended application would
typically include its verification and configuration management to maintain its suitability for use.
RMC Workshop Long Beach, 16 – 17 July 2014
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PRODUCT ACCEPTANCE SOFTWARE
Make a Plan
What to Test –
Native, IGS, STP
GD&T using Artifact
321 Alignment using Artifact
Best Fit using Artifact
Scale (temperature compensation)
Security
Planning Includes:
Purpose of Test
Scope of Test
Description of the Test
Result of Test - PASS/ FAIL
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PROCUREMENT CONTROL
Do I flow down DPD requirements and have adequate oversight
of my sub-tiers?
How Does Boeing Document Supplier Compliance?
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Control of Measurement Equipment
Do I have complete procedures for all my Coordinate
Measurement system equipment?
CMS requirements are as follows:
1. Provide a method to complete or a procedure for calibration of measurement equipment.
2. Provide an inventory list for your measurement systems including scale bars, adaptors, thermometers and
equipment.
3. Provide an operator reference parameter guideline for equipment handling, set-up, field checks and
establish special targeting and target adapter requirements
4. Provide documented acceptance criteria for use of scale factors to compensate measurements for
coefficient of thermal expansion and to verify accuracy as well as establish, transform and manipulate
coordinate systems establish data collection parameters and requirements.
5. Provide a process for data analysis, format, storage and reporting.
6. Provide training syllabus with curriculum to assure those using the equipment have
been adequately educated on the use of CMS and PAS as well as Boeing requirements.
RMC Workshop Long Beach, 16 – 17 July 2014
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INSPECTION MEDIA
Is my CMS data aligned to engineering datums or datum targets?
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Inspection Media
8.4.1. Supplier’s QA must verify that all design requirements; e.g., all features defined by
feature control frames, annotation, specifications, notes and other specified requirements
in the authority MBD dataset and associated parts list including dimensional and other
properties are identified and planned for inspection/validation.
RMC Workshop Long Beach, 16 – 17 July 2014
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Datum Alignment

A 3-2-1 datum scheme or datum reference frame is comprised by the following:
–
The primary datum feature relates the part to the datum reference frame by bringing a minimum of three
points on the surface into contact with the first datum plane. See Fig. (a).
–
The part is further related to the frame by bringing at least two points of the secondary datum feature into
contact with the second datum plane. See Fig. (b)
–
The relationship is completed by bringing at least one point of the tertiary datum feature into contact with
the third datum plane. See Fig. (c)
Note: Actual X,Y, Z callout can change as long the alignment is to the Primary, Secondary and Tertiary datum.
Fig. (a)
Fig. (b)
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Fig. (c)
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Datum Alignment

A 3-2-1 requires mutually perpendicular planes (primary, secondary, and tertiary datum planes).

This 3-2-1 Rule defines the minimum number of contact points necessary to properly locate a part.

If Datum targets are called out, these datum points usually have basic dimensions locating them. With Model
Based Definition, the basics may not be shown, but they are implied.

Engineering Datum features are usually related to the actual function or relationship of other parts being
assembled.
RMC Workshop Long Beach, 16 – 17 July 2014
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Datum Alignment
 CMS Datum Alignment
Example 1
– The Nominal (model data) and
Actual (as inspected) datum
values A1, A2, A3, B1, B2, C1
show little to no Delta (deviation)
when aligning to the part datum
features.
– Note the location of the 4 Out of
Tolerance (OT) hole location
conditions.
* Not all inspection points are shown
for illustration purposes.
RMC Workshop Long Beach, 16 – 17 July 2014
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Best-Fit Alignment
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Best-Fit Alignment

Best-Fit simply takes the operator chosen alignment features and spreads their error equally around all the
chosen alignment setup features. Best-Fit allows you to choose certain features to concentrate on the
alignment direction.

Best-Fit alignment is used to align inspection data to the CAD model. Best-Fit alignment looks at all the
scanned data and does an average fit to the CAD model.

Best-Fit Alignments can only be used if the engineering dataset is NOT datum controlled.
NOTE: When GD&T callouts exist on the engineering dataset, you must use a datum alignment for product
acceptance. The GD&T callouts will direct you to the associated datum alignment requirements.
RMC Workshop Long Beach, 16 – 17 July 2014
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Best-Fit Alignment
 CMM Best Fit Alignment to
inner surface points to make
Out of Tolerance (OT) holes
CONFORMING - Example 1A
– Assume a Best Fit Alignment
direction to the inner surface along
B1 & B2 was used due to an out of
tolerance hole (h1, h2, h3, h4)
location condition when setup to
the established Datum features.
NOTE: This particular Best Fit
alignment will shift the Actual B1
and B2 datum locations from the
inner surface values causing the
actual alignment values to be nonconforming. BUT the 4 holes will
now be CONFORMING.
* Not all inspection points are shown
for illustration purposes.
RMC Workshop Long Beach, 16 – 17 July 2014
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MODEL BASED DEFINITION
Are my FAIs complete – Have I accounted for all explicit and
implicit design characteristics?
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TRAINING
Have all employees working with DPD or MBD been trained in the
DPD or MBD requirements that apply to their specific area of
responsibility?
Copyright © 2009 Boeing. All rights reserved.
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Summary:
In this presentation, we have reviewed the following
FAA Identified DPD Non-Conformances:
DOCUMENTED PROCESSES
NOTIFICATION OF DPD CHANGES
CONFIGURATION MANAGEMENT AND MEDIA SECURITY
CAD SYSTEM
PRODUCT ACCEPTANCE SOFTWARE
PROCUREMENT CONTROL
CONTROL OF MEASUREMENT EQUIPMENT
INSPECTION MEDIA
MODEL BASE DEFINITION
TRAINING
Please see brochure or contact RMC to receive one.
RMC Workshop Long Beach, 16 – 17 July 2014
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END
RMC Workshop Long Beach, 16 – 17 July 2014
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Boeing Defense, Space & Security
Supplier Quality
1
2D Drawing Examples- Note: CATIA V4
models are made up of 255 layers like a book.
Some pages contain reliable KUTD
info…some don’t and are marked.
2
This Drawing indicates
ALL layers in the 3D
model are use-able for
manufacturing and
inspection
BOEING is a trademark of Boeing Management Company.
Copyright © 2009 Boeing. All rights reserved.
3
This Drawing indicates ALL
layers in the 3D model are
use-able for manufacturing
and inspection
EXCEPT LAYERS 161 and
162
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CATIA V5 CAT.part
CATIA V4.model
RMC Workshop Long Beach, 16 – 17 July 2014
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Configuring Conversions
RMC Workshop Long Beach, 16 – 17 July 2014
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Sub-tier Control Example
Sub-tier Supplier Activity – how one aerospace company controls.
The Boeing tier 1 supplier will flow down the requirements of D6-51991 or
equivalent document to sub-tier suppliers and document sub-tier supplier
compliance when Boeing authority datasets or dataset derivatives are
used for manufacturing or product acceptance.
RMC Workshop Long Beach, 16 – 17 July 2014
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Sub-tier Control – Use a Checklist
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Sub-tier Control – Maintain Records
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Sub-tier Control – Maintain Detail Information
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Implicit vs. Explicit
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IMPLICIT FEATURES
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