AEROSPACE
QUALITY MANAGEMENT SYSTEM
9100
Dale K. Gordon
Past Chairman
Americas Aerospace Quality Group
SAE Aerospace Committee G-14
September 25th 2002
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
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Aerospace Quality System
Standards

INTERNATIONAL STANDARDS
– 9100 - Quality System for Aerospace
Manufacturers
– 9101 - Checksheet for 9100
– 9110 - Quality System for Aerospace Repair
Stations
– 9111 - Checksheet for 9110
– 9120 - Quality System for “Pass-Through”
Distributors
– 9121 - Checksheet for 9120
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Aerospace Quality Standards
(cont.)
Other Projects
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)








AS9003 - “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
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HISTORY OF 9100
Background - Early to mid1990s

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
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U.S. Industry Response - 1995
Supplier Management and Quality Assurance professionals from:
AlliedSignal
Boeing
GE Engines
Lockheed Martin
McDonnell Douglas
Pratt & Whitney
Rockwell Collins
Rolls-Royce Allison
Sundstrand
Northrop Grumman
Sponsors
• Aviation/Space & Defense Division of
American Society for Quality
• SAE Aerospace Council
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AAQG Members Agree
“Where aerospace quality is
concerned...there is no
competitive advantage”
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Writing Team Formed
Inputs
AS9000:1997
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AEROSPACE SUPPLY
CHAIN
Suppliers are
NOT
Homogenous
Tier 1
Vehicle / Airframe /
Propulsion Manufacture
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
Tier 5 - Distributors (Fasteners, Raw Materials,
Commodities, Adhesives, Special Materials)
Tier 6 - Raw Materials (Castings, Forgings, Sheet, etc)
Dale K. Gordon
Company
Specific or
NADCAP
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Global Quality Standard
Activity
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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
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International Quality System
Standard Creation 1998
Americas
Standard
AS9000
ISO 9001
1994
European
Standard
prEN 9000-1
World Aerospace Quality
Standard ; AS/EN/JIS Q 9100
AS9100
ISO TC 20
WG11
Dale K. Gordon
EN 9100
13
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
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AEROSPACE SUPPLY
CHAIN
Tier 1
Vehicle / Airframe /
Propulsion Manufacture
9100
9110 for
Repair
Stations
Tier 2
Integrators /
Source Control/
Software Dev./
Major Assemblies
9003
9120
Variation Reduction
FAI
Process Proving
Tier 3 - Integrators /
Source Control / Specialty
Electronics / Wiring / Compnts
Tier 4 - Make to Print / Machine Shops
/ Processors
Tier 5 - Distributors (Fasteners, Raw Materials,
Commodities, Adhesives, Special Materials)
Tier 6 - Raw Materials (Castings, Forgings, Sheet, etc)
Dale K. Gordon
Company
Specific or
NADCAP
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Year 2000 ISO 9000 Revisions
A moving target . . .
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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 9100 - est. June 2001

AS9100A published by SAE in August 2001

JIS Q 9100:2001 published by JSA in November 2001
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ISO 9001:2000 - Model of a process
based quality management system
Continual Improvement of the Quality Management System
CUSTOMER
CUSTOMER
Management
Responsibility
Management
Responsibility
input
Requirements
Management
Responsibility
Product
Realization
Product
Satisfaction
output
Value added activities
Information Flow
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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
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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
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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.”
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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.
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Dale K. Gordon
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.
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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
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9100 Checklist - 9101

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
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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)
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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
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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
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.
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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
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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.
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International Requirements for
Certification
Single
global standards
9100
Oversight/control
by IAQG
and Sectors
Inter-National
Aviation Authority
endorsement
One audit
accepted by
all Primes
Harmonised systems
of application
Inter-National
Accreditation
control
International Aerospace
Supplier Quality System
Evaluation/Certification
Active Industry
participation
Data easily
available to all
participants
Global
acceptance by
supplier base
Dale K. Gordon
Approved
Cert. Bodies&
Registrars
Approved
Aerospace
Auditors
32
Basic structure of the system
International Aerospace Audit Approval
Process
IAQG Scheme issued by SAE / AECMA / SJAC
IAQG “oversight” WHAT
requirements
Americas
(equivalent)
Americas Scheme
oversight
Accreditation Body
Registrars
Auditors
Asia
(equivalent)
Asia Scheme
Suppliers
Accreditation Body
Registrars
Auditors
Suppliers
Accreditation Bodies
Registrars
Auditors
Assessment
Suppliers
data
Data Base
Access
Usage
Aerospace Industry Participants
HOW
oversight
Assessment
data
Data Base
Europe Scheme
oversight
Assessment
Europe
data
Data Base
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 24281 (Europe)
– SBAC TS157 (UK)
– SJAC 9010 / 9011 (Japan)
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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
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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.
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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
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QUESTIONS
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