Supplier flow down and FAI webcast

Transcription

1 Supplier flow down and FAI webcast July 2014

2 Agenda Introduction Overview Flow downs Quality clause overview Matrix AS9102 FAI overview AS9102 FAI training (forms 1, 2 and 3) Additional AS9102 requirements Conclusion and questions 2

3 Meggitt flow down requirements Why are they necessary? Contract requirements are mandated by Meggitt s customers and Meggitt is contractually obligated to flow specific Contract and Quality requirements to our sub-tier suppliers. Customer requirements (Government and Commercial) are changing Government: Prime contract flow downs are required for suppliers and sub-tiers pursuant to the applicable FAR and DFAR clauses. Commercial: Long term agreements/purchase order requirements from Meggitt customers require flow downs to Meggitt suppliers. Meggitt is required to comply with all flow downs i.e. quality, engineering, and contract terms, and ensure that our sub-tier suppliers are compliant. Annual Certifications and Representations are required, have been sent out and will incorporate additional flow downs. If your annual certifications and representations are not completed by the due date Meggitt may not be able to place a PO with the supplier. 3

4 Quality clause flow down overview Quality clauses will be flown down on all purchase orders (MSS-OC Form No , Rev. Y (or latest Rev on line)). Quality clauses will represent the details behind the quality requirements for each purchase order. It shall be the responsibility of the supplier to review and agree to adhere to all the quality clauses prior to accepting the purchase order contract. ** for international import shipments only** In accordance with the Terms and Conditions that govern this purchase, international shipments must comply with all US Customs Laws and Regulations. The Commercial Invoice must clearly state importer name as Meggitt (Orange County) Inc., PO #, part number, clear description of the good, US 10-digit HTS classification, unit of measure, quantity, unit price, currency, county of origin, terms of sale, and Incoterms Unless excluded, articles and their containers, shipped to the US must be permanently marked with the country of origin. If your annual certifications and representations are not completed by the due date Meggitt may not be able to place a PO with the supplier. Pre-Alert Information must be sent to: Tradecompliance.mssoc@meggitt.com and include the Customs Invoices, the transportation Airway or Ocean Bill of Lading and any other documents required for US Customs clearance requirements. Purchase Order quality requirements may be found at: 4

5 Quality clause flow down overview Standard Quality Clauses (per Form , Rev. Y): 1 Conformance to Quality Requirements 2 Conformance to Quality (ISO 9001 or AS9100) 3 Distributor Inspection Requirements 7 Request for Deviation Q08 Inspection Evidence (10 yr. min. record retention) 10 FAI 12 Certification of Compliance 18 Fabricated Items Certification of Raw Materials 22 Part Identification Requirements 26 Right of Access to MSS-OC, their Customer s and/or Regulatory Authorities 27 Supplier Notification Requirements 28 Foreign Object Debris / Damage 29 Counterfeit Part Prevention 30 Inspection Sampling Plan 5

6 Quality Clause Matrix (for Meggitt internal use) 6

7 AS9102 FAI training 7

8 AS9102 FAI overview AS9102 Rev B - Aerospace first article inspection requirement 1 Conformance to Quality Requirements 2 Conformance to Quality (ISO 9001 or AS9100) 3 Distributor Inspection Requirements 7 Request for Deviation Q08 Inspection Evidence (10 yr. min. record retention) 10 FAI 12 Certification of Compliance 18 Fabricated Items Certification of Raw Materials 22 Part Identification Requirements 26 Right of Access to Meggitt, their Customer s and/or Regulatory Authorities 27 Supplier Notification Requirements 28 Foreign Object Debris / Damage 29 Counterfeit Part Prevention 30 Inspection Sampling Plan 8

9 AS9102 FAI overview AS9102 Rev B - Aerospace First Article Inspection Requirement Invoked by AS9100: 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).as9102 FAI training (forms 1, 2 and 3) Additional AS9102 requirements Conclusion and questions 9

10 Definition FIRST ARTICLE INSPECTION (FAI): A complete, independent, and documented physical and functional inspection process to verify that prescribed production methods have produced an acceptable item as specified by engineering drawings, planning, purchase order, engineering specifications, and/or other applicable design documents. Ref AS9102 Rev B 10

11 Purpose Provides objective evidence that: All engineering design and specification requirements are Understood Accounted for Verified Documented Process and manufacturing validation 11

12 Quality is EVERYTHING 12

13 FAI Introduction Video 13

14 When FAI should be performed Full FAI New part introduction New supplier or new location or manufacture Lapse in production for more than 2 years When required by customer Partial (Delta) FAI Design change Significant change in the method of manufacture (e.g. tooling, processes, machine, location, numerical control program, sequence of manufacture). 14

15 FAI exceptions Standard parts If supplier can provide evidence (CofC) that part has been qualified to procurement specification such as MS, NAS. Electronic components If parts being supplied have been manufactured by a supplier listed on Qualified Products List (QPL) for that part. Non custom parts (COTS). Commercial off the shelf (COTS) items 15

16 What is included Verification of all design characteristics Material and special process certification Manufacturing process verification Nonconformance resolution FAIRs for major subassemblies 16

17 AS9102 forms The following forms comprise a First Article Inspection Report (FAIR) AS9102 Form 1: Part Number Accountability shall be used to identify the part that is being first article inspected (FAI part) and associated sub-assemblies or detail parts. AS9102 Form 2: Product Accountability Raw Material, Specifications and Special Process(s), Test Verification shall be used if any material, special processes or functional testing are defined as a design requirement. AS9102 Form 3: Characteristic Accountability, Verification and Compatibility Evaluation shall be used to record an actual measurement or inspection/ verification of the FAI part for every design characteristic on the drawing, including notes. Note: The standard Form 3 in this tutorial has been modified to include a column for the recording of measurement equipment used during the inspection of the FAI part. 17

18 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes F O R M 1 9. Manufacturing Process Reference 10. Organization Name 11. Supplier Code 12. P.O. Number 13. Detail FAI 14. Full FAI Baseline Part Number including revision level Partial FAI Assembly FAI Reason for Partial FAI: a) if above part number is a detail part only, go to Field 18 b) if above part number is an assembly, go to the INDEX section below. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number YELLOW or LIGHT GREY fields MANDATORY information required. BLUE or DARK GREY fields CONDITIONALLY REQUIRED. These fields must be completed when information is available. WHITE fields OPTIONAL information required when available. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete 19. Signature By 20. Date 21. Reviewed By 22. Date 23. Customer Approval 24. Date Form 1, 9102 Rev B, Date: Oct 06,

19 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes 9. Manufacturing Process Reference FAI 19 part, not reflected by the current part/drawing revision level. 10. Organization Name 11. Supplier Code 12. P.O. Number Box 1. Part Number of the FAI part. Box Detail Name FAI of the 14. Full part FAI as shown Baseline Part on Number the including drawing. revision level Partial FAI Assembly FAI Reason for Partial FAI: Box 3. Serial number of the FAI part. a) if above part number is a detail part only, go to Field 18 b) if above part number is an assembly, go to the INDEX section below. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number Box 4. The Report No. Box 5. The revision of the part being first article inspected. Indicate if there is no revision. Note: The latest revision (Box 7) does not always affect all parts contained on a drawing. Box 6. The drawing number associated with the FAI part. (if different from part number) Box 7. Reference the revision engineering drawing. (if drawing number is different from part number) Box 8. Reference ECO or VMRR authorized changes affecting the 19 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for

20 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes 9. Manufacturing Process Reference 10. Organization Name 11. Supplier Code 12. P.O. Number 13. Detail FAI Assembly FAI 14. Full FAI Baseline Part Number including revision level Partial FAI Reason for Partial FAI: a) if above part number is a detail part only, go to Field 18 b) if above part number is an assembly, go to the INDEX section below. INDEX Box of part numbers 9. Reference or sub-assembly internal numbers required manufacturing to make the assembly noted above. 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number process and Rev used. Box 10. Name of the organization performing the FAI. Box 11. Reference the supplier vendor code. Box 12. Reference the customer Purchase Order number. Box 13. Check as appropriate. Box 14. Check as appropriate. For Partial FAI provide the baseline drawing number, including issue status and the reason. i.e Change of manufacturing location, Non-Conformance, Process change, Design change etc. 20 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition.

21 1. Part Number 2. Part Name 3. Serial Number 4. FAI Report Number 5. Part Revision Level 6. Drawing Number 7. Drawing revision level 8. Additional Changes 9. Manufacturing Boxes Process 15, 16, 10. Organization 17 and Name Supplier this Code section 12. is P.O. Number only Reference required if the Part Number in Box 1. is an Assembly with lower level parts. 13. Detail FAI Assembly FAI 14. Full FAI Baseline Part Number including revision level Partial FAI Reason for Partial FAI: a) if above part number is a detail part only, go to Field 18 b) if above part number is an assembly, go to the INDEX section below. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number 16. Part Name 17. Part Serial Number 18. FAI Report Number Box 15. Reference all lower level parts or next level sub-assembly Part Number. Box 16. Part name as shown on the drawing/ parts list. Box 17. Reference the serial number of the part. Box 18. A reference number that identifies the FAI package. 21

22 Box 19. The name and signature of the person who prepared the FAI. Box 20. Date when the FAI was prepared. Box 21. The name of the person who reviewed or approved the FAI package. Box 22. Date when the FAI was reviewed. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: FAI complete FAI not Complete 19. Signature By 20. Date 21. Reviewed By 22. Date 23. Customer Approval 24. Date Form 1, 9102 Rev A, Date: Oct 24, 2003 Box 23. Customer Approval. Box 24. Date of Customer approval. 22

23 1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number 5. Material or Process Name 6. Specification Number 7. Code 8. Special Process Supplier Code 9. Customer Approval Verification (Yes/No/NA) 10. Certificate of Conformance number F O Boxes 1-4 are repeated on all forms for convenience and traceability. R M Functional Test Procedure Number 12. Acceptance report number, if applicable 13. Comments Prepared By 15. Date

24 1. Part Number 2 Part Name 3. Serial Number 4. FAI Report Number 5. Material or Process Name 6. Specification Number 7. Code 8. Special Process Supplier Code 9. Customer Approval Verification (Yes/No/NA) 10. Certificate of Conformance number Box 5. Enter the name of the material or process i.e. Aluminium Alloy, Cadmium Plate etc. Box 6. Enter the material or process specification number, class and material form i.e. AMS4928 Bar (Include make from materials, weld/ braze filler materials, standard catalogue hardware etc). Box 7. Reference any material code specified. Box 8. Reference Special Process Supplier Vendor code. Box 9. Indicate if technical approval is required by the customer. Box 10. Reference Certificate of Conformance number(s) e.g. Special Process, Raw material & Mill certifications, Laboratory Reports etc. 24

25 11. Functional Test Procedure Number 12. Acceptance report number, if applicable Box 11. Reference the Functional Test procedure as stated on the drawing. Box 12. Reference the Functional Test report. 13. Comments 14. Prepared By 15. Date Box 13. Comments As applicable. Box 14. The name of the person who prepared this form. Box 15. Date when this form was completed. 25

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27 Ballooned drawing A ballooned drawing is a required element of a FAIR package to support Box 5 of Form 3 Identify 100% of contracted* characteristics: Balloon and number all dimensions Balloon and number all surface finish callouts Including exclusion and inclusion area callouts Balloon and number all material and hardness callouts Don t forget the requirements identified in the title boxes at the bottom of the drawings Note callouts are identified as such on form 3, e.g. note1, note 2, etc. *If part is shipped incomplete per the Purchase Order (PO), Statement Of Work (SOW) or approved Vendor Material Review Request (VMRR), account for the excluded characteristics by indicating in balloon or adjacent to note the coded reason. 27

28 Ballooned example 28

29 Form 3 completed 29

30 F O R M Boxes 1-4 are repeated on all forms for convenience and traceability. 3 30

31 Box 5. Assign a unique number for each design characteristic. In most cases this identifier is from the ballooned drawing. Box 6. Reference the drawing zone (include Sheet No. and Section). Box 7. Reference any zoned characteristics i.e. Key Characteristics, Sealed features, Datum features etc. 31

32 Box 8. Indicate the specified requirement for the design characteristic i.e. Dimensional features with minimum and maximum value of tolerance, Drawing notes, Specification requirements etc. 32

33 Box 9. Indicate measurements obtained for each design characteristic. Multiple characteristics shall be listed as individual values. All drawing notes must be accounted for. Processes that require design verification must have statement of compliance recorded on the form i.e. Certification of Compliance state Accept. Laboratory reports or Certificate of test must show specific values for requirements and actual results. 33

34 Box 10. Record the tool identification number of specially designed tooling used as a media of inspection. Box 11. Record non-conformance document reference number if any design characteristic is found non-conforming. Box 14. Reference measurement equipment used for FAI. (Note: The standard Form 3 in this tutorial has been modified to include a column for the recording of measurement equipment used during the inspection of the FAI part and is required only if requested. ) Box 12. Name of the person who prepared this form. Box 13. Date when this form was completed. 34

35 AS9102 forms continued AS9102 forms can be downloaded at SAE AS9102 FORMS FAI completion and verification Results compiled by person independent to process Results reviewed independently and signed Frequently asked questions from IQAG website AS9102 frequently asked questions FAI support and documents Documents for suppliers 35

36 Thank you 36 MSS Strategic Plan Presentation 5 th July 2011 Meggitt Sensing Systems. Proprietary.