A Practical Field Guide for AS9100C
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About this ebook
What separates this field guide from most other books on AS9100 and its implementation are the flow charts showing the steps to be taken in implementing a QMS to meet a sub-clause’s requirements. You need to turn out aerospace conforming parts on time, every time, and at a competitive cost, as that's exactly what the companies that can compete now and in the future will do. A Practical Field Guide for AS9100 will help to get you there.
Erik V. Myhrberg
Erik V. Myhrberg has 25 years of experience within the area of international management system standards as auditor, consultant, advisor, and member of U.S. Technical Advisory Groups (TAGs) TC 207 and TC 176.
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A Practical Field Guide for AS9100C - Erik V. Myhrberg
A PRACTICAL FIELD GUIDE FOR AS9100C
Also available from ASQ Quality Press:
A Practical Field Guide for ISO 9001:2008
Erik Valdemar Myhrberg
ISO 9001:2008 Explained, Third Edition
Charles A. Cianfrani, John E. Jack
West, and Joseph J. Tsiakals
ISO Lesson Guide 2008: Pocket Guide to ISO 9001-2008, Third Edition
J.P. Russell and Dennis R. Arter
ISO 9001:2008 Internal Audits Made Easy: Tools, Techniques, and Step-By-Step Guidelines for Successful Internal Audits, Second Edition
Ann W. Phillips
Process Driven Comprehensive Auditing: A New Way to Conduct ISO 9001:2008 Internal Audits, Second Edition
Paul C. Palmes
ISO 9001:2008 Interpretive Guide for the Design and Construction Project Team (e-Book)
Prepared by members of the ASQ Design and Construction Division and edited by John R. Broomfield
How to Audit the Process-Based QMS
Dennis R. Arter, John E. (Jack) West, and Charles A. Cianfrani
The ASQ Auditing Handbook, Third Edition
J.P. Russell, editing director
Quality Audits for Improved Performance, Third Edition
Dennis R. Arter
The Quality Toolbox, Second Edition
Nancy R. Tague
Mapping Work Processes, Second Edition
Bjorn Andersen, Tom Fagerhaug, Bjornar Henriksen, and Lars E. Onsoyen
Lean Kaizen: A Simplified Approach to Process Improvements
George Alukal and Anthony Manos
Root Cause Analysis: Simplified Tools and Techniques, Second Edition
Bjorn Andersen and Tom Fagerhaug
The Certified Manager of Quality/Organizational Excellence Handbook, Third Edition
Russell T. Westcott, editor
To request a complimentary catalog of ASQ Quality Press publications, call 800-248-1946, or visit our Web site at http://www.asq.org/quality-press.
A PRACTICAL FIELD GUIDE FOR AS9100C
Erik Valdemar Myhrberg
with
Dawn Holly Crabtree
and Rudolph RE
Hacker
ASQ Quality Press
Milwaukee, Wisconsin
American Society for Quality, Quality Press, Milwaukee 53203
© 2010 by ASQ
All rights reserved. Published 2010
Printed in the United States of America
Library of Congress Cataloging-in-Publication Data
Myhrberg, Erik V.
A practical field guide for AS9100C / Erik Valdemar Myhrberg ; with Dawn Holly Crabtree and Rudolph RE
Hacker
p. cm.
Includes bibliographical references.
ISBN 978-0-87389-793-8 (alk. paper)
1. Aerospace engineering—Quality control—Standards. 2. Aerospace industries—Management. 3. ISO 9000 Series Standards. I. Crabtree, Dawn Holly. II. Hacker, Rudolph. III. Title.
TL671.28.M94 2010
629.10684—dc22 2010021511
EPUB ISBN: 978-1-63694-201-8
No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.
ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange.
Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, video, audio, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005.
To place orders or to request ASQ membership information, call 800-248-1946. Visit our Web site at http://www.asq.org/quality-press.
asq-logo-quality-press-address-blackWe dedicate this combined work
to our loving families.
Table of Contents
COVER
TITLE PAGE
COPYRIGHT
CONTENTS
PREFACE
SECTION 4: QUALITY MANAGEMENT SYSTEM
4.1 General Requirements
4.2 Documentation Requirements
SECTION 5: MANAGEMENT RESPONSIBILITY
5.1 Management Commitment
5.2 Customer Focus
5.3 Quality Policy
5.4 Planning
5.5 Responsibility, Authority, and Communication
5.6 Management Review
SECTION 6: RESOURCE MANAGEMENT
6.1 Provision of Resources
6.2 Human Resources
6.3 Infrastructure
6.4 Work Environment
SECTION 7: PRODUCT REALIZATION
7.1 Planning of Product Realization
7.2 Customer-Related Processes
7.3 Design and Development
7.4 Purchasing
7.5 Production and Service Provision
7.6 Control of Monitoring and Measuring Devices
SECTION 8: MEASUREMENT, ANALYSIS, AND IMPROVEMENT
8.1 General
8.2 Monitoring and Measurement
8.3 Control of Nonconforming Product
8.4 Analysis of Data
8.5 Improvement
CONCLUSION
AS9100 DOCUMENTED REQUIREMENTS BY SECTION
GLOSSARY
REFERENCES
PREFACE
With the dawning of the twenty-first century, companies are being pushed to the extremes of their limited resources. At one time it was sufficient to meet most of our customer’s requirements, but not now. On a global scale, we are all being asked to do more with less—and for less. At some point soon the current internal systems will not be able to hold back the deluge, and companies will be faced with a stark decision—consistently improve or perish.
Companies, teams, and individuals are still trying to meet customer expectations in an effective and efficient manner, worldwide competition still drives the need for innovation, and internal process pressures still demand continual improvement in order to remain functional. One of the best and most widely accepted ways in which companies can face these challenges is to implement an effective and efficient quality management system, which not only adds value to the organization but also satisfies the customer.
It is extremely challenging to stay competitive in the aerospace industry; the need for assurance of good material is paramount and has driven cost, sometimes unnecessarily due to the continued existence of outdated manufacturing and quality system thinking and practices. Cost is primarily due to small order quantities, product complexity, and special processes and materials. Yet, traditional production, overinspection, and processing techniques are also extremely costly, as typically many redundant tests of the same feature occur to assure conformance.
When MIL-Q-9858 was retired, the aerospace industry started to feel the ill effects of the absence of aerospace-specific mandated criteria. Though many companies registered to ISO 9001, which provided a fantastic yet generic business quality management system, it did not address the needs of the aerospace industry. To those of us who could see the wastes in the traditional product realization
system, the creation of AS9000, and subsequently AS9100 based on ISO 9001, was by divine providence. Here was a QMS that focused on process control that is efficient and effective, not redundant inspection, and communicated the industry-specific needs of aerospace—such as first inspection and product traceability. When ISO 9001 became a process-oriented standard in the year 2000 it better supported the process control structure of AS9100; hence, AS9100:2001 is the best QMS standard for aerospace—bar none!
From working with and within aerospace primes, medium-size suppliers, job shops, and software design, it has become apparent how little the concept of process control has caught on. Combining the experience of over 150 QMS implementations with responsibilities covering internal and supplier quality engineering, and training and implementing of lean manufacturing and Six Sigma quality, we readily see how businesses could avoid long-term costs of redundant non-value-adding tasks like inspections, scrap, rework, and customer returns by following the requirements of AS9100 using proven quality tools. AS9100 is not prescriptive, but gives hints as to the use of these tools.
The purpose of this field guide is to assist the reader, step by step, in implementing a QMS in conformance with AS9100. This field guide has been created in order to facilitate an inner reliance between senior management, middle management, functional teams, and the individual. Users of the field guide will find within it practical tools, tips, and techniques useful for not only implementing a quality management system but also for maintaining one.
In keeping with ISO 9000’s definition of quality
as the degree to which a set of inherent characteristics fulfils requirements,
we have identified the requirements and inherent characteristics (distinguishing features) of AS9100. Within this field guide, each subclause containing requirements is the focus of a two-page spread that consistently presents the features listed below.
Provisions (or What the Field Guide Will Do)
Provide a user-friendly guide to AS9100’s requirements for implementation purposes
Identify the documents/documentation required, along with recommendations on what to consider retaining/adding to a QMS during AS9100 implementation
Guide internal auditor(s) regarding what to ask to verify that a conforming and effective QMS exists
Direct management on what it must do and should consider to satisfy AS9100’s enhanced requirements and responsibilities for top management
Depict step by step what must occur to create an effective, conforming QMS
Direct Characteristics (or What the Field Guide Provides)
The standard—A paraphrase of what a subclause of AS9100 requires in easy-to-understand language, with references to information in ISO 9000 and guidance in ISO 9004 to enhance the user’s understanding of what AS9100 requires and what possible added steps the user can take to improve performance (per the ISO 9004 guidelines)
Document requirements—A list of the documentation/documents required by the subclause, with some ideas to consider in satisfying those requirements that will take the system beyond the requirements toward continual improvement
Internal audit questions—What every internal audit team needs to ask at a minimum when assessing the QMS for conformance with the subclause
Management summary—A concise description of what management must do and/or is responsible for in order to achieve conformance to the subclause, along with some guidance on additional steps management can take to enhance the system
Process control tip—Recommendations of method or tools to best infuse process control into the QMS, as AS9100 was intended to be used
Subclause flowchart—A depiction of the steps that need to be undertaken during an implementation/transition effort to effectively and efficiently satisfy the requirements of the subclause of AS9100,