Aerospace Surveillance Audits

Airplane, aerospace, AS9100

Question

In reference to AS9104/1 clause 8.2.2.f “Auditing of the entire AQMS standard on all shifts is required for initial and recertification audits. For surveillance audits, the planning shall include coverage of multiple shifts, when the audit plan activities occur across multiple shifts.”

The identified process is “Production” but shift one conducts assembly and shift two kits parts for assembly. Since “Production” spans both shifts but “activities” are distinct on each shift, do you have to audit both shifts during every surveillance audit?
Answer

It would be required that Production be audited on both shifts when it is planned for surveillance audits.  For example, if the acquire business, design & development, and procure parts/materials were audited in Annual Surveillance #1 and production and procure parts/materials were audited in Surveillance #2, then second shift would only require to be audited during Surveillance #2.

Buddy Cressionnie

Learn more about the AS9100 standards here.

Using White Out on Controlled Documents

ISO documentation practices, requirements

Question

During our certification for AS9100C the auditor found some documents with correction liquid that we have used for years. We have prohibited the use of any type of correction on all processes company wide.

It is common that during the prototype stage we performed dozens of changes due to the differences between the calculating/design program (electrical) and what happens in real life. During those adjustments we change manually circuits, values, etc. from the original version, with white-out tapes (before was liquid paper) once the prototype works those changes are incorporated as “Initial release” in the package that goes out for manufacturing. Do you guys see any problem using white out tape / correction tape on the controlled copies during prototype stage? My point is that the original values are recorded on the originals that will be obsoleted and the new ones on the initial release, keeping the controlled copies marked as records of the prototype.

Response

Thanks for contacting ASQ’s Ask the Experts program.

With regard to your inquiry, changing the documented results of inspection or test activities should be avoided or at least strictly controlled.  This is of special importance if these records are intended to provide evidence of product or process conformance.

However, prototype test results which may be subject to frequent changes during preliminary inspection or test activities, doesn’t require the same level of control.  These results are usually intended for informational purposes only and not for final acceptance of a process or product.

Bill Aston
ASQ Senior Member
Managing Director of Aston Technical Consulting Services
Kingwood, TX
http://www.astontechconsult.com

AS9100 Audit

Training, completed training, competance

Question:

I have recently started work at a company that is registered to AS9100. My previous employer was registered to ISO 9001 and I was trained as an internal auditor.

What additional training is required to audit to AS9100? (other than learning the standard).

Does my previous training in internal quality auditing qualify me to audit to the AS9100 standard?

Are the standards for auditor different for AS9100 than ISO 9001?

Response:

The ISO 9001 and AS9100 requirement for internal auditors are the same; that the auditor be competent. The organization determines the competence requirements for its internal auditors. Typically, the competence includes both knowledge of the standard and internal audit methodology.

Buddy Cressionnie
International Aerospace Quality Group Americas AS9100 Lead
Voting member of the U.S. TAG to ISO/TC 176
Southlake, TX

Additional ASQ Resources

AS9100 Keeps Bosch Communications Flying High in Aerospace Industry
by Janet Jacobsen
Abstract: In 2006, the Bosch Corporation acquired Minnesota-based Telex Communications, Inc., a supplier to the aerospace industry. This business became known as Bosch Communications Systems. Boeing, a key customer for Bosch Communications’ aviation headsets, issued a requirement for all suppliers to become certified to AS9100, the international quality management system standard for the aerospace industry. To satisfy Boeing’s requirement, Bosch Communications launched an ambitious initiative to achieve dual AS9100/ISO 9001 certification in less than one year. Bosch contracted with ASQ to provide AS9100 lead auditor and internal auditor training to educate a cross-functional team about the standard and prepare them for the auditing process. In October 2008, just 11 months after launching its certification effort, Bosch earned both AS9100 and ISO 9001 certification.

Road to Revision- The path ahead for updating the AS9100 series of standards
by Buddy Cressionnie
Abstract: The flagship aviation, space and defense quality management system (QMS) standard has started revision activities. AS9100—Quality management systems—requirements for aviation, space and defense organizations is the foundation standard of the International Aerospace Quality Group (IAQG).

The AS9100C, AS9110, and AS9120 Handbook (ebook)
by James Culliton
Abstract: AS9100, AS9110, and AS9120, the quality management system (QMS) standards for the aerospace industry, are written in the most ambiguous language possible. Indeed, they don’t outline how they should be implemented. Those decisions are left to the organization implementing their requirements or, in some cases, to a consultant.

Although some consultant firms for aerospace systems are excellent, there are many that purport to be experts yet proffer systems and processes that are either in contravention to the standards’ requirements or so unwieldy that they render the process impotent.

In an effort to simplify these issues, this book proposes practices that have been described as opportunities for improvement or best practices by registration auditors in the past. It includes a discussion of each of the three standards’ clauses, suggests best practices to comply with them, outlines common findings associated with them, and provides an overview of the changes to AS9100C from AS9100B.

AS9100 Temperature Control

Temperature control

Question:
There is a form for recording the temperature etc. of the measuring and calibrating equipment, but should there also be a requirement that the temperature be set at 20 degrees Celsius as that is the temperature in which all the calibrated equipment (gauge blocks etc.) would be accurate in?

Does an AS9100 certified company require a temperature controlled room for which to house all equipment and also in which all critical measurements are taken place?

Response:
The AS9100 states that environmental conditions shall be suitable for the calibration, inspection, measurement, and testing being carried out.  If the measuring equipment is measuring close tolerance dimensions (typically .0001 inch) then expansion coefficients of materials must be considered including temperature and humidity.

Buddy Cressionnie
International Aerospace Quality Group Americas AS9100 Lead
Voting member of the U.S. TAG to ISO/TC 176
Southlake, TX

AS9100C

Question:

Question: The AS9100C, which is an expansion of the ISO 9001:2008, states that a “process” based system is being promoted as is shown in 0.2 of the Introduction.  Why are 3rd party auditors being required to use the AS9101 Quality Management Systems Audit Requirements for Aviation, Space and Defense Organizations checklists for their audits?  These check lists are not “process” based and go back to the old procedure systems of the 1994 standard.

Each of our core processes consists of a flow chart of the process, process turtle and PEAR.  If you were doing a true process audit you would take these documents and perform the audit and not limit the auditor to being “boxed in” by a check list.  If the QMS has been developed correctly the process approach audit will allow you to cross other processes when being performed.

Response:

Thanks for the question.  The IAQG AS9101 Team does firmly believe in promoting the process approach which you will see reflected with the next AS9101 revision.  I agree that auditors should follow the process while performing all auditing (including 3rd party audits), yet it is also important to ensure that all the AS9100 requirements are satisfied.  That is why AS9100 auditors are trained to audit the process and then complete the Objective Evidence Record to ensure all AS9100 requirements are fulfilled.

Thanks,
Buddy Cressionnie
Americas 9100 Lead

AS9100C: Scoring the Aerospace QMS

Q: I’m reviewing the scoring method used for auditing AS9100 Rev. C  – Requirements for Aviation, Space and Defense Organizations, and I don’t see any verbiage to show what would be considered an acceptable overall score. I’m curious to know if the score is more subjective to the discretion of the auditor or if the threshold for “acceptable” or “not acceptable” exists somewhere as a guideline. Thank you to anyone able to offer insight.

A: The AS9101D auditing standard (currently not sold by ASQ) has scoring to provide an indicator of how robust your quality management system is operating (QMS), which is based upon the findings identified during your audit.  There is not a required score to “pass” the audit and receive certification.  The AS9101D score is recorded in the OASIS database, which your current and potential customers may review.

AS9100C  requires the use of the AS9101D auditing standard, which has eliminated scoring.

Buddy Cressionnie
International Aerospace Quality Group Americas AS9100 Lead
Voting member of the U.S. TAG to ISO/TC 176
Southlake, TX

Editor’s note: Looking for additional resources on AS9100 auditing? Check out AS9101D Auditing for Process Performance: Combining Conformance and Effectiveness to Meet Customer Satisfaction
 

AS9100 production rough card

Q: According to our customer requirement, our quality inspectors are signing each step in production rough card in the following way: they apply their personal stamp (which includes their first and last name and personal number), add add a manual signature and date. I tried to convince our customer to give us permission to eliminate the manual signature (as the personal stamp and date are enough), but he doesn’t agree with me.

Is there any official standard for this procedure? I was not able to find any special requirement for this in AS9100 Rev. C  – Requirements for Aviation, Space and Defense Organizations.

A: The AS9100 standard does not dictate any specific method of recording that a production step (clause 7.5.1) or verification step (clause 8.2.4) is complete. AS9100 does require the organization to comply with customer requirements. So this is a requirement which you need to discuss with your customer.

Buddy Cressionnie
International Aerospace Quality Group Americas AS9100 Lead
Voting member of the U.S. TAG to ISO/TC 176
Southlake, TX

AS9100 Rev. C Document References

Airplane, aerospace, AS9100

Q: My organization is getting ready for our registration audit to AS9100 Rev. C  — Requirements for Aviation, Space and Defense Organizations.  There is a debate regarding procedures and the document references with those procedures.  If the procedure does not mentioned a document within the body of the document we normally do not include it in the reference section of the procedure.  Our internal auditor says that we should reference all documents that show linkage in the process approach.

For example, the auditing procedure references corrective action, preventive action, etc., but does not have any of the document mentioned in the body of the procedure.

Can you settle this matter? Our auditor says that we will get a finding if this is not done.

A: The process approach is more than including references to documents, especially with AS9100 revision C requirements to identify your product realization processes.  I would encourage you to examine some guidance materials available on the ISO website:
Introduction and support package: Guidance on the concept and use of the process approach for management systems action procedures, but the narrative of the procedure does not include how these procedures tie into the auditing practice?  It would seem that the auditing procedures body should support the referenced procedures and explain how they are applicable within the auditing process.  If I was your auditor, I would issue an observation or opportunity for improvement for that condition.

Your first paragraph seems to indicate the reverse scenario.  If a document is not referenced within the body of the document, then it is not a referenced procedure.  Yes, that appears reasonable.

It is a good practice to show the interrelationship of documents to include parent-child relationships and referenced documents when appropriate.

Buddy Cressionnie
International Aerospace Quality Group Americas AS9100 Lead
Voting member of the U.S. TAG to ISO/TC 176
Southlake, TX

Value of CQA Certification in Aerospace Auditing

 

Q: What groups recognize the ASQ Certified Quality Auditor (CQA) Certification? The CQA is not enough to conduct an  internal audit to AS9100:2009 Revision C Quality management systems—Requirements for aviation, space and defense organizations, and I am not trained in AS9100C.

Why become a Certified Quality Auditor (CQA)?

A: Thank you for contacting ASQ Ask the Experts. The ASQ CQA is recognized by companies, industries and organizations worldwide as evidence of an individual that has demonstrated their ability to meet established criteria for quality management system auditing.

AS9100C contains requirements that are specific to the aerospace industry and  exceed the ASQ CQA requirements.

Having an ASQ CQA would be a good start toward obtaining an AS9100C auditor certification.  However, keep in mind that although first party internal auditors should be trained as auditors, rarely would they be required to be certified for the purpose of conducting internal (first party) audits.  I hope this helps.

Bill Aston
ASQ Senior Member
Managing Director of Aston Technical Consulting Services
Kingwood, TX
www.astontechconsult.com