Boeing Supplemental Oversight

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1 Boeing Supplemental Oversight Auditor Day - Italy Marco Pellegrini Date: 19 th September 2014 BOEING is a trademark of Boeing Management Company. Copyright 2005 Boeing. All rights reserved. 1

2 Introductions Marco Pellegrini Boeing Commercial Airplanes Supplier Quality United Kingdom With Boeing since 2006, BOR since

3 Boeing Supplier Quality / BOR Function BOEING is a trademark of Boeing Management Company. Copyright 2005 Boeing. All rights reserved.

4 Boeing Supplier Quality / BOR Organizational Relationship within Boeing

5 Boeing Supplier Quality Supplier Quality Organization Responsibilities Global organization, supporting suppliers in all regions Americas, Europe, Asia-Pacific Responsibilities Quality Management System (QMS) and Special Process approval and maintenance Recognition of certification Performing assessments Validating product and process conformance to requirements Supplier development, including training and performance improvement Customer Complaints resolution and corrective action Personnel competencies include QMS (ISO9001/AS9100) and auditing (ISO19011)

6 Boeing Supplier Quality Supplier Quality Field Rep Responsibilities Product conformance Source acceptance (prior to shipment) In-process inspections and special inspections Conformity Inspection (as applicant and/or FAA designee) First Article Inspection (FAI) Verification Assessments Quality Management System Product Manufacturing Processes Special Processes Digital Product Definition Tooling Software

7 Boeing Supplier Quality / BOR Function Boeing Oversight Representative (BOR) Responsibilities BOR Team Staffed by Supplier Quality Field Representatives Additional work statement and responsibilities Qualified individual who meet the requirements of Other Party Assessor s per AS Responsibilities Support SQ Field Representative questions/issues/concerns regarding certification recognition Analyze/monitor CB performance using client (Boeing supplier) performance (CB Report Cards) Perform supplemental oversight described in , 7.13 Maintain Records of supplemental oversight Attend/support aerospace industry certification scheme groups and meetings IAQG, AAQG, Other Party Management Team (OPMT), etc. Present supplemental oversight results, conduct training workshops, etc. Support IAQG initiatives and standards AS9101 Rev D, AS9102 FAI, AS9100, etc.

8 Boeing Supplier Quality / BOR Function BOR Representatives and Location T. Coulter (BCA) T. Chisholm (BCA) T. Marino (BDS) M. Pellegrini (BCA) G. Barnes* (BCA) BOR Team Lead BOR Team Member * Limited support as needed R. Borrelli (BDS) L. Price (BDS) B. Aldrich (BCA) T. Cupples (BCA) J. Johnson (BDS) D. Castaneda (BDS) A. Levhar* (BDS) K. Hara* (BCA) T. Lee (BCA) B. Simons* (BCA)

9 BOR Team Structure SQIT Executive Sponsors BCA George Buswell BDS Larry Weng Process Leads BDS Tony Marino BCA Tim Lee m US/Canada Oversight Representatives Robin Borrelli Tom Coulter Dan Castaneda Linda Price Terry Cupples Bruce Aldrich Jerry Johnson Tom Chisholm BDS, East BCA, West BDS, West BDS, California BCA, California BCA, East BDS, West Winnipeg International Oversight Representatives Marco Pellegrini BCA, Europe Brian Simons BCA, Asia* Kinsuke Hara BCA, Japan * Gordy Barnes BCA, Europe * Avihay Levhar BDS, Israel * * Limited support - as needed

10 BOR Team Management Tools Internal - SharePoint EITMS Group Mail Box Activity Log External - Team Managed OASIS Account 10

11 Boeing Supplier Quality / BOR Function BOR Team Communication with CB Boeing Oversight Representatives hold the Responsibility, Accountability and Authority at Boeing to communicate with CB and Accreditation Body (AB) via the OASIS Feedback Loop on Certification Activities. BOR Team primarily uses OASIS for communication, informal follow-up may be made via and/or phone calls. OASIS FEEDBACK LINKAGE USED TO Manual Automated BOR Rep requests / inputs information in OASIS Boeing Integrated Supplier Information System (ISIS) automatic upload to OASIS BOR / CB follow-up communication resulting from a ISIS Upload Communicate CB report card Notify of supplemental oversight activity. Coordinate general inquiries regards certification status Communicate when a Major nonconformance is issued against a suppliers QMS. Communicate when a supplier is put on Probation CB EXPECTATIONS Utilize report card data as needed on focus areas. Respond to inquiries within 1 month (per AS9104) Review affected AS9100 elements for Major SER s issued at next on-site Conduct short notice audit when a supplier is placed on probation

12 Boeing Supplier Quality / BOR Function BOR Process Summarized OASIS MANUAL FEEDBACK OASIS AUTOMATED FEEDBACK Audit Report Review CB OVERSIGHT ACTIVITY AS9101 Reports Onsite Assessment at Supplier Client Validation (Audit Report Review & QPA 119) CB Office Visit Working together and supplier file review CB Witness Audit Auditor competency 12

13 Boeing Supplier Quality / BOR Function BOR Team Communication with CB 13

14 Data Drives BOR Activities BOR Support request BOR activity Log (might result in) Supplemental Oversight 14

15 Data Drives BOR Activities CB report cards CB Report Cards - Risk Based Management Used to identify high risk CB s based on client performance data (X) and side of client base (Y). Data is pulled directly from ISIS Distributed by the BOR team to the applicable CBs every 6 months Includes Detailed Definition of Metrics (SER, NOE, Client List Data) Measure level of influence (Boeing suppliers on Y axis) 17 Performance Measures ( X axis) Number of Clients Increase Over Time SER's MAJOR / SER's Minor NoE's (#) BEST Quality rating (average) Probation (past 12 months) CB Form D Major/Minor (12 mos) Product NCR's (6 months) RCCA (#) Elevation to AB (#) CB s are advised to utilize the detail data worksheets provided in the Report Card to identify performance issues of clients listed. This may include but not be limited to. Identifying AS9100 elements of a organization that may warrant further review Determining Audit time applied depending on the quantity of issues identified 15

16 Data Drives BOR Activities CB report cards Risk Based Management CB Report Card Data fed into risk analysis tool. Used to identify high risk CB s based on client performance data and side of client base. 16

17 Tips on Using the CB Report Card Data Tip 1: Use SER data for affected clients when developing the audit plan. This data includes Minor and Major QMS Nonconformance's including the affected AS9100 element. Tip 2: Use NoE data for affected clients when developing the audit plan

18 ICOP supplemental oversight BOEING is a trademark of Boeing Management Company. Copyright 2005 Boeing. All rights reserved.

19 2013 ICOP Oversight Supplemental Activity Results Supplemental CB Oversight Events (58 Completed) 13 CB Office Visit 2 Europe, 1 Japan 7 Witness Audits 36 Adhoc Events Upon Request Client Validations, Audit Report Reviews, Certificate Authentications Industry Shared Oversight Activity (Industry commitment met) 2 office visits complete 3 witness audit complete 1 RAB QSA office audit 2 Market Surveillance Events Results: 27 Form D nonconformance's generated by Boeing CB Corrective action required Coordinated with Accreditation Body (AB) and will be verified during CB office visits CB concerns elevated to ANAB for resolution Boeing Executive Engagement 19

20 CB Performance Nonconformance Activity (AS Form D) Breakdown of Form D s issued by Boeing during Boeing Supplier and CB Surveillance activities. Form D s issued by Boeing are taken into consideration of CB s Report Card.

21 2014 ICOP Oversight Plan CB Risk Analysis Risk Analysis BORDER Calculations 22 Red CBs 15 - Americas 6 Europe 1 Japan Planned Oversight for Red CB's Office Visits = 16 (Red CB with No 2013 Office Visit or X value > 350) Client Val = 6 (Red CB with 2013 Office Visit and X value < 350) 21

22 BOR update supplemental oversight activity - Europe Updated: 15 th Sep 2014 UK: 4 CB Office visits conducted in the UK 2 Boeing only 6 NCRs raised (2 Major) 1 with UKAS 6 NCRs raised by UKAS 1 with ANAB 2 NCRs raised by ANAB 1 CB witness audit planned for Sep Elevation to AB Europe (other than UK): 2 CB Office visits conducted in Europe (Italy, France) 2 Audit report reviews (Form N) conducted in Europe (Italy, Germany) (all Boeing only) 6 NCRs raised (3 Major) 1 CB witness audit planned for Nov Elevation to AB

23 BOR update - general feedback (Europe) Observed areas of general concern: Management of NCRs Weak corrective actions plans to NCRs raised, accepted by auditors Poor verification conducted (often remotely). Verified execution of corrective actions, not the effectiveness. Audit Calculation Minimum audit days utilized, without justification (required by ) Certification Structure Eligibility Criteria E.g.: campus affecting audit duration Control of local (overseas) offices for clients in Asia Inconsistent grading of NCRs classification, appearance of less thorough audit 23

24 Boeing Supplier Quality Requirements and Processes BOEING is a trademark of Boeing Management Company. Copyright 2005 Boeing. All rights reserved.

25 Boeing Supplier Quality Requirements and Processes Customer Requirements Boeing utilizes contract/purchase order notes to flow down requirements BDS contract notes are available on external web-site BCA contract notes are available on internal (Boeing Partners Network) web-site. The table at right is a example of some of the Key, top level contract requirements which Boeing flows down to its suppliers. These are accessible on the external web. BCA BDS D Boeing Quality Management System Requirements for Suppliers D Boeing Approved Process Sources D Quality Assurance Standard for Digital Product Definition at Boeing suppliers AS9102 X31764 First Article Inspection BCA Quality Purchasing Data Requirements N/A

26 Boeing Supplier Quality Requirements and Processes D Quality Management System Requirements Key Points in D Supplier is required to obtain certification/registration through an accredited Certification Body. Depending on the type of product/services provided, different sections of D may be applied. Contract/PO Notes are used to defined which sections apply. Boeing reserves the right to change Boeing approval status of a supplier and/or to terminate the recognition of the Seller s certification, regardless of previous or current recognition. Supplier is required to notify Boeing when: Supplier changes a CB Certification is suspended or withdrawn by a CB Boeing identified findings and seller s quality performance data is provided to the CB during certification, registration and surveillance activity. Seller receipt of Boeing QMS nonconformance that is classified as Major, against Seller's QMS, Seller shall coordinate with the CB in order to provide awareness and description of Corrective Action taken In the event that Boeing changes Seller s approval status from Approved to Probation or Disapproved; Seller will notify their CB within five business days and make arrangements for a Special Short-notice Audit (Reference ISO paragraph 9.5.2, AS9104A / AS9104/ ). This audit scope will include investigation of nonconformities that resulted in the change of status to Probation or Disapproval and assessment of impact to certification.

27 Boeing Supplier Quality Requirements and Processes Customer Satisfaction Clients can demonstrate Boeing (Customer) Satisfaction via three applications with the Boeing Partners Network system. APPLICATION ISIS Integrated Supplier Information System BEST Boeing Enterprise Supplier Tool ASAP Automated Source Activity Planning System USED FOR Communication of Quality Management System (QMS) findings on Supplier Evaluation Report (SER). Communication of Product Nonconformance issues found within the Boeing Factory. Communication of a supplier s performance at the Boeing Enterprise, Group and Site levels. Recording of Source Acceptance Results (accept and reject) Recording of Boeing pick-ups (SRD Supplier Rejection Document) at Source Note: ASAP will migrate over to ISIS system in 2016.

28 Boeing Supplier Quality Requirements and Processes Customer Satisfaction - ISIS AUDITING TIP: Ask the client to show their ISIS application, check for Past due nonconformance review or C/A activities. Stated Corrective Action plans followed. Select a product nonconformance and determine if client has addressed the issue.

29 Boeing Supplier Quality Requirements and Processes Customer Satisfaction - BEST AUDITING TIP: Have the Supplier access the BEST application. Note: only specified account holders may have a BEST application typically Quality and/or Program mgmt. If the supplier has contracts with multiple Boeing sites drill down and review the Group Performance ratings. Clicking on the Quality and Delivery hyperlinks will provide specific rejection documents, trace this within the suppliers C/A system. Does the Management Review include the Group Performance (i.e. individual sites) as well as the Composite Rating (Boeing Enterprise)?

30 Boeing Supplier Quality Requirements and Processes Customer Satisfaction - ASAP AUDITING TIP: If Boeing Source Acceptance is a contract requirement: Ask the supplier to show the ASAP application Have them run a report of source pickups (SRD Source Rejection Document). Determine if the SRD data is used for corrective action activities.

31 Communications CB Awareness Information Tri-folds OASIS (General Feedback, Major Nonconformance, Probation) Customer Satisfaction (ISIS-BEST-ASAP) Boeing external Websites (Boeing Quality Management Systems requirements) OASIS_Tri_Fold Customer satisfaction External websites BPN (Boeing Partner Network) BPN Customer Overviews (FAA/DCMA/NASA) IAQG Committees (AAQG/EAQG/APAQG) 31

32 Questions 32

33 Questions??? We welcome feedback on our process. The following Boeing Oversight Group account may be utilized to provide feedback, ask questions or raise a complaint/concern: Thank you for supporting this activity!!!

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