2.4 This QAIS comments on the Hawker Beechcraft s approach to Nadcap and its significance in achieving and thence maintaining HBQSC approval.

Transcription

1 QAIS No.Q5B-008H SUBJECT: CONTROL OF SPECIAL PROCESSES 1. Purpose 1.1 The purpose of this Instruction is to provide guidance for both Suppliers of raw material and those undertaking or wishing to undertake processes which Hawker Beechcraft Quality Support Company (known hereafter as HBQSC) have deemed to be critical and thus require special attention. These carry the generic term Special Processes. 2. Scope 2.1 This Instruction applies to Suppliers wishing to supply Raw Material/undertake Special Processes, and to those currently doing so in support of the Hawker Jet programme. 2.2 This QAIS is applicable to both Suppliers manufacturing product to Hawker Beechcraft supplied Approved Engineering data (known hereafter as Subcontractors) and, where applicable to producers of certain Raw Materials. 2.2 This document provides guidance for new applications for Special Process/Raw Material production approval and the requirements for ongoing surveillance of the approvals issued. It also identifies how an existing Supplier undertaking Special Processes/Raw Material supply can request a variation or an extension to their current Scope of Approval in line with the needs of the Hawker business. 2.3 This QAIS also provides a Listing (see Appendix C) identifying those raw materials and Special Processes that must be verified by HBC during First Article Inspection Reporting 2.4 This QAIS comments on the Hawker Beechcraft s approach to Nadcap and its significance in achieving and thence maintaining HBQSC approval. 3. References The Documents listed below are all available for download at the Hawker Beechcraft website see supply_chain/qa/proforma/ This Instruction is an integral part of the following HBC ESCO Training Modules:- Core Module X1 HBQSC Basic Requirements Awareness Training - Quality Assurance Module B - Supplier Assessment Module D - Supplier Assessment and Surveillance Special Processes Module E - Supplier Surveillance Hawker Beechcraft Corporation Quality Assurance Instruction No QSDC NO:Q5B-000 Section 8h Page 1 of 14

2 HBQSC Form No. HBIFSAS/QA/SC3 Firms Application for Approval Quality Assurance Instruction to Suppliers Doc Ref Q5B-001A Issue of Mandatory Hawker Beechcraft Documentation to Suppliers Quality Assurance Instruction to Suppliers Doc Ref Q5B-005B Control of Subcontractor Workpackage Changes. Quality Assurance Instruction to Suppliers Doc Ref Q5B-007B and Addendum Personal Authorisation Quality Assurance Instruction to Suppliers Doc Ref Q5B-010B Corrective Action Quality Assurance Instruction to Suppliers Doc Ref Q5B-010C Quality Alert/Letter of Disclosure Quality Assurance Instruction to Suppliers Doc Ref Q5B-015C Supplier Evaluation and Surveillance Process Check Report (Special Process Audit Checklists) HBQSC/QA/ SCXXX series see Appendices A and B HBQSC Form No. Q7B-457 (obverse and reverse) Non Conformance/ Corrective Action Request 4. Procedures 4.1 General Information and Background The Hawker Beechcraft Corporation (known hereafter as HBC), has maintained close control on its Suppliers undertaking what are termed Special Processes and to those supply certain Raw Materials. Appendix A of this Instruction identifies all Special Processes/Raw Material Approval Categories covered by this QAIS. The first and second columns of Appendix A show the Approval Category Code and Description for each Special Process. The Approval Category Codes are awarded upon successful evaluation of the Special Process to the individual Candidate Company and are listed in Section Four within the Certificate of Approval issued by the HBC UK Quality Manager s Office. The third column details the Special Process Check Reports (aka Checklists) which are used to assess, and thence monitor the Special Process. Appendix B of this Instruction identifies the Process Checklist reference, its Description and its Issue. It also cross-refers to the Reference Specification from which the Checklist has been derived. The final column details the Approval Category Code(s) described above, covered by the Checklist e.g. to audit Zinc Spraying to BAEP 1517 and thus achieve a 4z Approval, Checklist No. HBQSC/QA/SC124(M) would be used. Likewise, this Checklist would also be used for subsequent surveillance of this process. Appendix C of this Instruction details those Special Processes/Raw Materials which must be verified as correct by HBC, or its Approved Delegates, during the compilation of a First Article Inspection Report (Sheet 5) in accordance with QAIS Q5B-009H First Article Inspection Report Requirements and associated Addendum. The Special Processes listed here have been deteremined to pose a high risk to the overall product integrity and/or QSDC NO:Q5B-000 Section 8h Page 2 of 14

3 characterised by the definition of true Special Processes detailed within AS9100 para Validation of Processes for Production and Service Provision The requirements of this Instruction are principally derived from the HBC Quality Assurance Instruction (QAI) Doc Ref , as amended. Whilst the overall Special Process control policy is flowed down from the parent company HBC, this QAIS has been compiled to directly address the uniqueness of the Hawker jet design, which in the main utilises company derived process specifications e.g. BAePs rather than national and/or military standards Following the HBC QAI policy, this QAIS too recognizes that Nacap are acceptable 3 rd party assessors of our Special Processes and Raw Material production; as such Nadcap approvals can be used to augment the overall approval of the Suppliers Special Process/Raw Material capabilities provided that the following requirements are met:- i) The Supplier being evaluated holds a current Nadcap approval for the Special Process/Raw Material capability in review for approval and, ii) The most recent Nadcap audit is reviewed, and is found acceptable to HBQSC Despite a Supplier holding the requisite Nacap approvals, HBQSC recognizes that as production approval holders for the Hawker jet aircraft, the ultimate responsibility for Special Process and Raw Material supply control is ours and we must continue to perform appropriate oversight of the process evaluation an surveillance process As a general principle, HBC look more favourably, when selecting Suppliers, upon those who have obtained/maintain the appropriate Nadcap approvals; as intended, this should ultimately lessen the burden on both the vendor and the HBC QA functions Where Suppliers wishing to undertake or are presently undertaking Special Processes/supplying Raw Material listed in Appendix A that do not have the requisite Nacap approvals, HBQSC, or its approved nominees (see QAIS Q5B-007B personal Authorisations will undertake the assessment and surveillance activities to support the award of the HBQSC approvals. 4.2 New Special Processor /Raw Material Supply Applications Where Companies wish to undertake a Special Process or supply Raw Material, application must be made in writing using Form No. HBIFSAS/QA/SC3 Firms Application for Approval details are given in the QAIS Q5B-015C Supplier Evaluation and Surveillance. The Application must state the Process/Material, the relevant lead specification, its issue and a brief overview of the reasons why the application is made. The Applicant will also state if the Process/Capability has been approved by Nadcap, the date it was awarded and the Specification/Material Type against which it was assessed. QSDC NO:Q5B-000 Section 8h Page 3 of 14

4 4.2.2 The Application will be reviewed within the Chester office; the Applicant will be duly notified of the result of the review and whether we wish to proceed further If the application is agreed in principle, the Applicant will be sent or asked to download from the HBQSC website, a Self Assessment Questionnaire Pack comprising of the following documents:- HBIFSAS/QA/SC20b Evaluation of a Suppliers Quality Inspection Organisation and Basic Procedures (or alternatively HBIFSAS/QA/SC10 Supplier Working Arrangements Plan ) HBQSC Doc Ref Q7B-519 Series Supplier Relationship Plan Where no appropriate Nadcap approvals exist, the requisite Process Check Reports (Audit Checklists) for the Special Processes/Raw Material capabilities approvals sought Once completed by the Applicant, the above stated forms will be returned as detailed in QAIS Q5B-015C Supplier Evaluation and Surveillance. A review will be held by HBQSC, its approved nominees and where applicable, with Process Specialists at HBC Wichita Materials Laboratory, to determine the evaluation strategy to be taken by HBQSC Where the process/capability has been successfully evaluated by Nadcap, the Supplier will ensure evidence of the Nadcap approval is appended to support the Questionnaire Pack. The HBQSC team will determine from the evidence provided the type of verification visit required, the scope of the audit and if nominated Approved Process Specialists can be used. (See Quality Assurance Instruction to Suppliers Doc Ref Q5B-007B and Addendum Personal Authorisation, as amended.) Where applicable, The Team will also conduct reviews of the PRI Nadcap website to establish the Supplier performance during and after the last Nadcap audit. The need to augment the assessment process with physical testing of the process/material will also be established. The Applicant will be notified of the progress, but it is envisaged that no process will be approved in less than 8 weeks Once the Applicant is verified to be compliant with all aspects of the HBQSC requirements and the level of verification satisfies the HBQSC team, the Supplier Relationship Plan (SRP) will be finalised and sent for agreement with the Applicant The approved Special Processor/Raw Material supplier will then be issued with a Certificate of Approval by the HBQSC UK QA office referencing within Certificate s Section Four, the Approval Category Code, its Description, the Specialist awarding the approval and the Approval Processor List (APL) reference number. The Certificate will also define any Limitations to the Approval which must be strictly adhered to e.g. limitations on whom the Supplier can supply to Upon the granting of Special Process/Raw Material Supply Approvals, the HBQSC Qualified Vendors List (QVL) will be amended accordingly. The QVL is available for download from the Hawker Beechcraft website (see QSDC NO:Q5B-000 Section 8h Page 4 of 14

5 4.2.9 The Special Processor/Raw Material supplier will then be expected to maintain the approval in accordance with the surveillance requirements detailed in section 4.3 below. 4.3 Existing Approvals - Surveillance Where Suppliers already hold an HBQSC approval for the Special Processes they presently undertake, Hawker Beechcraft will require all approvals to be maintained as detailed below/overleaf Every 24 months (every 12 months in the case of nominated Prime Suppliers), the Special Processor/Raw Material Supplier will be ed the agreed Supplier Relationship Plan developed between the Supplier and HBQSC, as detailed above. This document will also contain reference to the corresponding Special Process Audit Checklists (as required e.g. for non Nadcap approved Processes/Organisations) that will need to be completed as part of the overall surveillance activity held by HBQSC upon its Special Processors/Raw Material Suppliers. As agreed with your HBQSC QA contact, the requisite Checklists will be sent to the Supplier, or downloaded from the HBC website. It should be noted that even where the Supplier holds the requisite Nadcap approvals, HBQSC still reserve the right to undertake oversight checks on Nadcap approved processes/capabilities; this may result in the need for the Nadcap approved Supplier also to complete the HBQSC checklists. All documents/checklists sent to the Supplier by HBQSC will be required to be reviewed by the Supplier, completed and returned to the HBQSC UK office within 4 weeks. The Supplier will also provide any supporting documentation such as Nadcap Approval Certificates and Nonconformance/Corrective Action Reports raised - see Para Important Note: Where Suppliers were not previously approved by Nadcap but have now successfully attained approvals in the interceding period between Hawker Beechcraft s audits, it is the Suppliers responsibility to immediately notify the HBQSC of the change of circumstance and request that the Nadcap approval be considered in lieu of completing the usual Process Audit Checklists Upon the documentation s receipt, the HBQSC team will conduct a thorough review. Where applicable, the HBQSC team will use the PRI Nadcap website to review the Suppliers performance during and after the Nadcap audits. Similarly, the HBQSC team will use Supplier performance data gathered from the HBC SAP system and from data gathered from the Supplier s own Customers (aka higher tiers) From the above review, the type of verification visit required, the scope of the audit and if nominated Approved Process Specialists are needed. See Quality Assurance Instruction to Suppliers Doc Ref Q5B-007B and Addendum Personal Authorisation, as amended. QSDC NO:Q5B-000 Section 8h Page 5 of 14

6 4.3.5 The need to augment the surveillance process with physical testing of the process/material will also be established Arrangements will be made to conduct the verification visit, as required with the Supplier Upon satisfactory conclusion of the surveillance activity, the EXSIS database and the HBC SAP system will be duly updated. 4.4 Non-Conformance Reporting and Corrective Action Planning In the event of a non-conformance being determined either by the Supplier s own internal audit function, somewhere within the Supply Chain or by the HBQSC team, both remedial and corrective action plans must be immediately agreed and implemented see QAIS Q5B-010B Corrective Action In the event of a severe non-conformance (Finding) being established, HBQSC acting under FAA rules, will expect the Supplier to place an immediate suspension order on the process affected and the extent of the problem understood and documented. The Supplier must inform the Conformity Manager, HBQSC at Chester immediately using the Quality Alert procedure defined within the QAIS manual (Re QAIS Doc Ref Q5B-010C Quality Alert/Letter of Disclosure ). 4.5 Special Process Scope Extension Petition If it is determined by the Supplier that they are requested to carry out Special Processes not covered by their scope of approval (as defined in Section Four of their Certificate of Approval issued by HBQSC), they must contact the Chester office to discuss the petition to extend their Scope of Approval. This petition process is defined within QAIS Q5B-005B Control of Subcontractor Workpackage Changes Again a review will be undertaken as detailed above, and where agreed, the Scope extension process will be established to add a further Special Process/Material Type. 4.6 Change of Circumstances The Supplier must notify the HBQSC team immediately of any proposed changes to the arrangements detailed within the Supplier Relationship Plan/Certificate of Approval. The change should be requested in good time to enable the HBQSC team to undertake the necessary investigation and report. The Supplier should allow 4 weeks for the change to be investigated and approved. In the event of a sudden changes occurring which are clearly beyond the control of the Supplier e.g. equipment failure, the Supplier again must notify HBQSC to discuss the alternatives to circumvent supply delays Failure to notify HBQSC of changes to the agreed arrangements laid out in the SRP will result in the withdrawal of the Suppliers Approvals and possible recall of any deliverables supplied outside the agreed arrangements provision at the Suppliers cost. QSDC NO:Q5B-000 Section 8h Page 6 of 14

7 4.7 Compiling Special Process Documentation The Supplier Relationship Plan The SRP is compiled in conjunction with the Certificate of Approval; it gives full details upon which the Approval has been issued. (see QAIS Q5B-001A Issue of Mandatory Hawker Beechcraft Documentation to Suppliers and QAIS Q5B-015C Supplier Evaluation and Surveillance ). The document comprises of six sections of significance to Special Process control is Section B(i) Categories of Approval and section B(ii) Approval Description/Limitations. Section B(i) is particularly significant as it details which Approval Categories are considered to be Special Process shown as a tick in the 4 th column. If the individual Suppliers own Nadcap approval has been accepted this too is ticked in the 5 th column. The 6 th column identifies the last date the Special Process was reviewed by HBQSC, or one of its approved Nominees - the 7 th column details the Process Check Report reference (APL No.) or the Nadcap Reference No. submitted as evidence of special process compliance. The 8 th column identifies any particular salient comments which relate to the approval granted. This is where information which affects the Process will be listed e.g. reference to an applicable Process Specification Departure (PSD). Section B(ii) details the Limitations of the Approval granted e.g. limited for specific part numbers and Customers. The Limitations are important and mandatory. QSDC NO:Q5B-000 Section 8h Page 7 of 14

8 4.7.2 The Process Check Reports (Supplier Self Assessment) The Checklist or Process Check Reports referred to in Para have been designed to enable th e Supplier to undertake an efficient self assessment of each approved Process in a structured and consistent manner. Some Suppliers have opted to embody these Checklists within their own internal audit processes. It is incumbent upon the supplier to report any ambiguities, lack of topicality or errors on the Checklist supplied to them by HBQSC The Special Process Assurance Plan has now been replaced by the inclusion a Process Quality Assurance Section at the start of each Checklist this Section requires the Supplier to check and attest that the QA Elements of the Special Process are being correctly maintained, on an individual process by process basis. This has been found to be a more robust and rigorous method of assurance Where a Process Check has been undertaken and non-conformances have been found, the Auditor will raise a NonConformance Report/Corrective Action Request. Where Suppliers are undertaking these Checks on a self assessment basis, the HBQSC Form No. Q7B-457 (obverse and reverse) Non Conformance/Corrective Action Request Non Conformance will be downloaded from the HBC Website (detailed at the start of this QAIS) for the purpose of recording the non-conformance and corrective action responses. These NC/CARs will QSDC NO:Q5B-000 Section 8h Page 8 of 14

9 be returned to HBQSC as part of the overall audit pack submission. Reference must be made to QAIS Q5B-010B Corrective Action for full details on the completion of the NC/CAR form The HBQSC Process Check Report is to be completed as shown in the examples detailed below. Once completed, the reports together with any documentary evidence and associated NC/CARs are to forwarded to your HBQSC QA contact at the following address :- Hawker Beechcraft Quality Support Company - Supplier Assurance Group, European Supply Chain Office, Hawarden Airport, Broughton, Near Chester, Flintshire, United Kingdom CH4 0BA Process Check Report - Page 1 Process Check Report - Pages 2 and Subs QSDC NO:Q5B-000 Section 8h Page 9 of 14

10 QAIS Q5B-008H - Appendix A; Special Process Designation QSDC NO:Q5B-000 Section 8h Page 10 of 14

11 QAIS Q5B-008H - Appendix A; Special Process Designation Continued. QAIS Q5B-008H - Appendix A; Special Process Designation Continued. QSDC NO:Q5B-000 Section 8h Page 11 of 14

12 QSDC NO:Q5B-000 Section 8h Page 12 of 14

13 QA IS Q5B-008H - Appendix B; Special Process C hecklists QSDC NO:Q5B-000 Section 8h Page 13 of 14

14 QA IS Q5B-008H - Appendix B; Special Process C hecklists Continued QSDC NO:Q5B-000 Section 8h Page 14 of 14

15 QA IS Q5B-008H - Appendix C; First Article Inspection Report Special Process and Raw Material Verification Listing The following Raw Materials/Special Processes have been identified as requiring verification by HBC (or approved Delegates) when completing Sheet 5 of the First Article Inspection Report (Form No. Q5B - 127E) See QAIS Q5B-009H First Article Inspection Report Requirements para Specification Process / Material Name Verification Requirement BAEP1514 CADMIUM PLATING STRESS RELIEF and EMBRITTLEMENT RELIEF AMS-QQ-P-416 CADMIUM PLATING STRESS RELIEF and EMBRITTLEMENT RELIEF QSDC NO:Q5B-000 Section 8h Page 15 of 14