1.2 This Instruction outlines the procedures to be adopted by Subcontractors to RA when applying for a concession.

Transcription

1 QAIS NO: SUBJECT: Q5B-010A CONCESSIONS 1 PURPOSE 1.1 Raytheon Aircraft (referred to as RA throughout this document), will not accept deliveries of products that do not conform to the requirements of the order, specification, drawing, etc., unless non-conformance has been authorised by an appropriate Concession/MRB Tag. 1.2 This Instruction outlines the procedures to be adopted by Subcontractors to RA when applying for a concession. 1.3 All Subcontractors holding Approval Category 18b, (MRB delegation) are subject to special requirements as annotated in paragraph 12 of this QAIS. 2 SCOPE 2.1 All non-conforming raw materials and/or manufactured goods (except propriety products) supplied or used in fulfilment of RA orders. 2.2 Requirements which are additional to or at variance with the basic procedure of this instruction are defined in the appendices of this instruction. 2.3 This instruction now defines the corrective action reporting procedure undertaken as part of the Concession application procedure. 3 REFERENCES Concession Application Form and Continuation Sheet (QSDC Nos and -2 respectively, see Appendices B1 and B2) pdf & pdf QAIS No.Q5B-010D Compilation, Approval and Amendment of a Material Review Board Plan for the Supply of Product to Raytheon Aircraft Company. Sect10d.pdf RAC Quality Assurance Instruction No Material Review Board Delegation Hawker Suppliers Concession Corrective Action Report (QSDC No. Q7B-557) Appendix C Q7B-557.pdf 4 DEFINITIONS 4.1 A Concession is defined as authority to accept a limited quantity of materials/parts already manufactured but which do not comply strictly with contract requirements (i.e., drawings, specifications, repair schemes or other design requirements). 4.2 A Concession can also request a deviation from the requirements of the contract/drwg/specification etc., before manufacturing is commenced. Such requests are strictly limited to the quantity/period quoted therein and any extension that may be required must be the subject of a further application. QSDC NO:Q5B-000 Section 10a Page 1 of 13

2 4.3 A Concession Corrective Action Report is a form completed and submitted by the Subcontractors quality authority as part of the Concession application identifying the root cause of the non-conformance and the corrective action taken to prevent recurrence. 5 APPLICATION PROCEDURE 5.1 Unless otherwise directed by the Quality Manager, Raytheon Aircraft Quality Support Company (known hereafter as RAQSC throughout this document), and an application for a concession shall be made by completing the following forms; ref RA Form QSDC Nos and -2, see APPENDICES B1/B These Concessions forms are available in electronic format using a Microsoft Word so were possible they can be created in this format. A template of the form is available on request via to scm_qa_uk@rac.ray.com 5.3 Each Concession Application shall be identified by the Subcontractors using their own Supplier Works Inspection Department (WID) Number. A register shall be maintained by the Subcontractor listing each concession raised and submitted, together with Raytheon Aircraft allocated Concession Serial Number of answered applications. The RAC Concession Serial Numbers of any previously answered concessions relevant to the item(s) in question, shall also be quoted where applicable. 5.4 A Continuation sheet (Form No ) can also form part of the Concession and can be used by either party to add additional details to the Front sheet. All Continuation Sheets used in the application for a Concession must refer to the Supplier WID Number. This Number must be clearly annotated on all Continuation Sheets used. Where sketches, rubbings, photographs are to be appended, the Applicant may scan the images and paste them on to the Continuation Sheets in order they can be transmitted. 5.5 Each Concession Application must relate to one drawing and part number only (handed parts excepted), although several items of the same drawing and part number may be included on the same form providing the discrepancies involved are of similar character (e.g., machining errors) and are separately identified against the specific items(s) involved. 5.6 Each Concession Application must be signed by the Subcontractor s approved Delegate this is normally the Subcontractor s Quality Manager or Chief Inspector. The approved Delegate will be identified by RAQSC once the individual has undergone the appropriate training (Refer to Basic Requirements Awareness Training Module X5 Non Conformance Management and Corrective Action ). 5.7 The Concession Application may be transmitted in its entirety to the RAQSC Design Manager (steve_boden@rac.ray.com). 5.8 Where a Subcontractor uses another RAQSC approved Subcontractor (subtier) to manufacture items, any concession applications from the second QSDC NO:Q5B-000 Section 10a Page 2 of 13

3 Subcontractor shall be referred to the primary Subcontractor s Quality Manager or his deputy, who is responsible for ensuring compliance with this instruction, before submission to RAQSC. 6 CONCESSION CORRECTIVE ACTION REPORTING AND CLOSE-OUT 6.1 Unless previously agreed to the contrary, the Subcontractor shall supply a Concession Corrective Action Report (Form QSDC No.Q7B- 557; see Appendix C) with every Concession application. This Report forms part of the Concession Application. 6.2 Each Concession Corrective Action Report shall be completed, in full, and approved by the Subcontractors quality authority as follows:- Box A1 Root Cause of Non Conformance For each non-conformance identified on the Concession application, enter the root cause of the discrepancy this must have been thoroughly investigated by the Subcontractor. Box A2 Owner Enter the name and title of the individual assigned the responsibility for implementing the corrective action. Box A3 Corrective Actions Enter details of the action taken to eliminate a recurrence of the discrepancy. Include details of any associated documentation e.g. Engineering Query Note, Tool Suspense Note numbers etc.. Box A4 EDC Enter the Estimated Date for Completion of the corrective action this is the time for the Corrective Action to be fully embodied. Box A5 Close Out Date Enter the date in which the corrective action has been successfully implemented and verified as effective. IMPORTANT NOTE: It is the responsibility of the Subcontractor to ensure that each Concession Corrective Action Report is fully closed out by verifying the corrective actions have been successfully implemented. The Concession Corrective Action Report must be reissued to RAQSC once the Report has been closed out. Failure to do so may result in any further Concession applications being denied or even the withdrawal of RA approval of the subcontractor. Box A6 Submitted by/title/date Each Concession Corrective Action Report must be signed by the Subcontractor s approved Delegate this is normally the Subcontractor s Quality Manager or Chief Inspector. The approved Delegate will be identified by RAQSC once the individual has undergone the appropriate training (Refer to Basic Requirements Awareness Training Module X5 Non Conformance Management and Corrective Action ). QSDC NO:Q5B-000 Section 10a Page 3 of 13

4 7 SEGREGATION OF NON-CONFORMING PARTS 7.1 All non-conforming items must be positively identified by a temporary method and retained in segregation until such time as the application is answered. 8 ACTION UPON RECEIPT OF ANSWERED CONCESSION 8.1 The Subcontractor s Quality Manager or his deputy is responsible for ensuring that any restorative or other actions required by the answered Concession Application Workbook are fully satisfied in all respects. 8.2 Where any required action is beyond the scope of the Subcontractor s approval qualification/capacity, the Subcontractor shall arrange through the relevant RA Materials Manager, for such action to be undertaken either at RA or another firm appropriately approved by RAQSC. 9 IDENTIFICATION OF NON-CONFORMING ITEMS 9.1 Non-conforming items shall be identified with the Raytheon Aircraft allocated Concession Serial number (NOT the Suppliers application number) adjacent to the Part Number using the marking method called for by the drawing. This identification shall be carried out for each individual part affected. 9.2 Where a Concession restricts an item to use for Test Purposes Only the item must be identified with: the Concession serial number a 1 wide red painted band, with the words For Test Only painted in white on the red band, unless the Concession specifies a test category and/or test number in which case the latter identification will apply. 9.3 Note: All Concession identification markings must be easily readable after final protective treatment. 10 INSPECTION HISTORY RECORDS 10.1 Where it is a RA requirement for the Subcontractor to provide these documents, the Raytheon Aircraft allocated Concession Serial Numbers are to be recorded in the appropriate section of the Inspection History Records. 11 RELEASE OF GOODS SUBJECT TO CONCESSIONS 11.1 All items subject to the Concession shall be despatched under cover of the appropriate type of release document which shall be clearly endorsed with the appropriate RA Concession Serial Number. IMPORTANT NOTE: RA will NOT accept deliveries subject to outstanding Concession Applications unless prior /written/fax permission has been given by the Quality Manager, RAQSC. In these cases, the Release Document must quote the authority / letter/fax reference and the goods clearly labelled to indicate the special QSDC NO:Q5B-000 Section 10a Page 4 of 13

5 condition, the outstanding Supplier WID Number, Raytheon Aircraft allocated Concession Serial Number (where available) and the Release Certificate number When an answered concession calls for the further work after delivery, the Supplier will clearly mark the affected parts/assemblies with a sticker or label stating Concession Work Outstanding (WO). This sticker/label will clearly state the Supplier WID Number and where applicable the Raytheon allocated Concession Serial Number(s) One hard (paper) copy of each applicable Concession shall be included with the applicable Release documentation. 12 CONCESSIONARY ACTIONS UNDERTAKEN BY MATERIAL REVIEW BOARD APPROVED ORGANISATIONS 12.1 Certain Primary Subcontractors have been approved to undertake the review and disposition of Concessionary or MRB action under the approvals granted to them by Raytheon Aircraft Quality and Engineering authorities (Re RAQSC Approval Category 18b ). The maintenance of this Approval is not only subject to the Approved Organisation providing acceptable means of compliance to meet the requirements of this QAIS, but also conforming to the requirements of the Raytheon Aircraft Company Quality Assurance Instruction No. QAI These requirements are addressed within the individual Subcontractor s specific Material Review Board Quality Plan (see QAIS Q5B- 010D) and are subject to annual on-site auditing by representatives of Raytheon Aircraft Quality and Engineering personnel Should any repair proposal have a potential impact which may cause comment / concern at a later build stage, a copy of the concession annotated suffix C will be forwarded to Mr Greg_Valcoure@rac.ray.com Quality Director Raytheon Aircraft Company, Wichita, And copy to bob_feazell@rac.ray.com a copy also being provided to neil_evans@rac.ray.com Quality Manager, Raytheon Aircraft Quality Support Company Ltd All Subcontractors approved to category 18b must forward completed Concession Applications to the Manager Engineering Liaison, Raytheon Aircraft Company, Wichita; electronic or hard copies of the original are to be retained by the delegate. 13 CANCELLATION OF, OR AMENDMENT TO, AUTHORISED CONCESSION In general, an answered Concession Application, authorised by allocation of a RA Concession Serial Number can only be cancelled or amended by submission of a further application which must make reference to the serial number of the original concession and clearly define the circumstances necessitating the cancellation. QSDC NO:Q5B-000 Section 10a Page 5 of 13

6 APPENDIX A Completing the Concession Application Workbook 1 APPLICATION FOR CONCESSION 1.1 Application may be submitted using electronic Form Number QSDC No and -2 via , see sections 5.2 and 5.7. If the supplier is not able to complete using this format a hard copy will be accepted. See Appendices B1/B2. 2 CANCELLATION/AMENDMENTS 2.1 Reference paragraph 13. Amendment or cancellations are made by resubmitting the original Concession for raise of issue. 3 IDENTIFICATION OF PARTS 3.1 In addition to the requirements of paragraph 9, where further work is to be carried out after delivery or in compliance with the RA Engineering (Design) Office recommendation, the Concession Serial Number will be suffixed WO. All parts must carry an appropriate sticker/label, bearing the concession number and suffix WO. The WO is not to be marked on the part. 4 COMPLETION OF FORM QSDC No Name of Subcontractor applying for concession. 2 Subcontractors Works Inspection Department Serial Number. 3 Raytheon aircraft type; e.g. Hawker 800XP or Hawker 800(U125a). 4 Aircraft Construction Number; e.g or assembly serial number if appropriate. If unknown write DETAIL 5 Purchase Order Number or Operation Number (Backshop). 6 Enter Cause Code as below:- 1. Design Errors 2. Tooling Errors 3. Handling 4. Operator Errors 5. Physical Properties 6. Engineering Methods 7. Breakdown of existing structures 8. Out-of-Stage Working NOTE: Cause Codes are used by the RA Quality and Engineering functions to determine individual trends and appropriateness of any applied corrective actions. It is most important that the Subcontractor carefully consider the Cause Code as part of the overall Root Cause analysis and associated corrective action as QSDC NO:Q5B-000 Section 10a Page 6 of 13

7 required by the Concession Corrective Action Report, appended to each Workbook. Cause Code 1 - Design Errors This code should only be applied once it has been fully determined that the associated Engineering/Design data is in some way discrepant and has led directly to the raising of the Concession Application. To annotate Cause Code 1, the applicant must identify in the Concession Corrective Action Report appended, the root cause as being an Engineering/Design error and the Engineering Query Note and / or Change Request application reference raised to address the anomaly. Cause Code 2 Tooling Errors This code should only be applied once it has been fully determined that the associated anomaly arose due to the use of the tooling provided. To annotate Cause Code 2, the applicant must identify in the Concession Corrective Action Report appended, the root cause as being a Tooling error and the Engineering Query Note and/or Tool Suspense Note reference raised to address the anomaly. Cause Code 3 Handling This code should only be applied once it has been fully determined that the associated anomaly arose due to incorrect or inappropriate handling of the component/assembly. Typically, this cause code will be apportioned to issues such as the item being accidentally dropped, scratched through poor protection, poor storage etc. To annotate Cause Code 3, the applicant must identify in the Concession Corrective Action Report appended, the root cause as being a Handling error and the Corrective Action must clearly define what has been done to prevent recurrence such as improved training, revised storage/routing procedures, better packaging etc.. Cause Code 4 Operator Errors This code should only be applied once it has been fully determined that the associated anomaly arose due to the Subcontractors operators incorrectly conducting some manufacturing operation. Typically, this cause code will be apportioned to irredeemable issues such as over-cutting, over-fettling etc.. To annotate Cause Code 4, the applicant must identify in the Concession Corrective Action Report appended, the root cause as being an Operator error and the Corrective Action must clearly define what has been done to prevent the Operator from causing this issue again. This action must be both positive and well considered; throw away statements such as Operator informed is not, in the majority of cases, considered to be adequate. In all cases informing the incumbent must be supplemented by additional training, Operator competence review etc. In all cases, evidence QSDC NO:Q5B-000 Section 10a Page 7 of 13

8 must exist that the Operator has understood and is now actively employing the training etc imparted to him/her. Cause Code 5 - Physical Properties This code should only be applied once it has been fully determined that the physical properties are in some way discrepant against the approved Engineering/Design data and has led directly to the raising of the Concession Application. To annotate Cause Code 5, the applicant must identify in the Concession Corrective Action Report appended, the root cause which has led to the failure to achieve the required physical properties. This typically may be such causes as bonded structures being under strength, over hardness following heat treatment etc.. Cause Code 6 - Engineering Methods This code should only be applied once it has been fully determined that in applying the prescribed Engineering Method, the resulting component was in some way discrepant against the approved Engineering/Design data. To annotate Cause Code 6, the applicant must identify in the Concession Corrective Action Report appended, the root cause which has led to the Engineering Methods failure to achieve the required product/parameter. This typically may be such causes as poorly written/described instruction planning instructions, incorrect methodology employed etc.. Cause Code 7 - Breakdown of existing structures This code should only be applied once it has been fully determined that in breaking down the existing structures, the resulting component was in some way discrepant against the approved Engineering/Design data. To annotate Cause Code 7, the applicant must identify in the Concession Corrective Action Report appended, the root cause which details why the structural break down caused the anomaly. This type of Concession may be unavoidable for some assembly types where breakdown can cause irrecoverable damage which must be concessioned e.g. when breaking down adhesively bonded structures. In all cases, the Subcontractor should examine why such structures need to be stripped in the first place and take corrective action accordingly.. Cause Code 8 - Out-of-Stage Working This code should only be applied once it has been fully determined that in conducting manufacturing operations outside of the normal scheduled production sequence, anomalies have arisen resulting in the component being in some way discrepant against the approved Engineering/Design data. To annotate Cause Code 8, the applicant must identify in the Concession Corrective Action Report appended, the root cause which details why the out- QSDC NO:Q5B-000 Section 10a Page 8 of 13

9 of stage working was necessary and why such out of sequence working should result in an anomaly. Note: Where the Supplier has used a subtier subcontractor who is responsible for a Concession, the Supplier will ensure: - the Concession Corrective Action Report and Root Cause analysis described above is flowed down to the responsible sub-contractor for them to provide the necessary investigation and CA statements. - the responsible subtier Subcontractor is identified in the Concession narrative (Field 20) 7 Identify if any further concessions have been raised on this particular component. 8 Originator s Name and clock/badge number 9 If above field is NO write N/A; if YES, detail the other RA Concession Serial Nos. and/or Suppliers WID Nos. that have been raised upon the affected component 10 Part Description/Title as per drawing. 11 Applicants department 12 Full part number and issue. 13 Date concession raised and approved. 14 Drawing number of affected Specification. Delete either Drg or Spec as applicable. 15 Originator s Telephone Number. 16 Serial or Batch Number of affected component. If more than one serialised component state See Sheet No. 2 and list continuation sheet Originator s address. 18 Quantity affected 19 Subcontractors approved Delegate Siganture normally the Quality Manager/Chief Inspector, as approved by RAQSC.. QSDC NO:Q5B-000 Section 10a Page 9 of 13

10 20 Clear and concise description of deviation from drawing of affected components. Sketches shall be used to illustrate area affected and provide dimensions. If required, separate Continuation Sheets shall be used. 21 Complete sheet numbering of all sheets etc. one sheet sheet 1 of 1, if two sheets sheet 1 of 2, sheet 2 of 2 etc. Fields A through J are for use by Raytheon Aircraft only and are to be left BLANK by the Applicant. A. Concession Serial Number allocated by Raytheon Aircraft and will be used to reference the Concession and identify the concession on all parts affected. B. Raytheon Aircraft Engineering department s determination and where applicable, the remedial action to be taken. Additional information may be added on the Continuation Sheets. C. Concession Category Category A is a Major Concession and will necessitate the raising of a modification to the Type Certificate data to accommodate the remedial part e.g. specifically designed and machined rib assigned to that particular Aircraft Manufacturers Serial Number. Category B are Minor Concessions which are determined to have no affect to the reliability, fit, form and/or function of the aircraft and as such do not necessitate the raising of a modification. Minor Concessions can be answered locally under the MRB Authority granted by Raytheon Aircraft to appropriately approved MRB delegates such as RAQSC Chester. D. Signature of RAC Engineer undertaking the review of the described anomaly and preparing the remedial action, if appropriate. E. Contact Telephone for above. F. Determination if the components Interchangeability (ICY)/functionality is affected typically, if ICY/functionality IS affected, the resultant Concession by definition would probably have to be classified as Major. G. Signature of appropriately RAC approved Design Engineer (approved to undertake MRB dispositions on behalf of RAC) H. Signature of appropriately RAC approved Design Specialist (approved to undertake MRB dispositions on behalf of RAC) J. Signature of RAC approved Quality Manager (approved to undertake MRB dispositions on behalf of RAC). If not approved Not Approved shall be written in this box before signing. QSDC NO:Q5B-000 Section 10a Page 10 of 13

11 APPENDIX B1 Front Sheet (Form No ) Concession Serial No. A Page 1 of 21 CONCESSION From 1 Supplier WID No. 2 APPLICATION IS HERBY MADE FOR A CONCESSION AS DETAILED BELOW Aircraft Type 3 Construction Number 4 Purchase Order No. or Operation No. 5 Cause 6 Any other Concessions raised on this Component: Yes / No 7 Originators 8 Name & No: Concession No.(s) 9 Part Description 10 Department 11 Part No / Issue 12 Date raised 13 Drawing or Specification 14 Originators Tel No. 15 No. Serial No./ Batch No. 16 Originators 17 Quantity Affected 18 Signature of Sub-Con 19 DESCRIPTION AND/OR SKETCH OF NON-CONFORMITY 20 Chief Inspector: DECISION AND/OR REMEDY CONCESSION CATEGORY A / B C B Important: Mark item with concession number adjacent to part number Prepared By D Tel E Functionality or ICY Affected/Not Affected F Design Approval Date G Form No Issued: 08/95 Revised 8/05 Specialist Approval Date H RAC Quality Manager approval Date J APPENDIX B2 Continuation Sheet (Form No ) QSDC NO:Q5B-000 Section 10a Page 11 of 13

12 CONCESSION CONTINUATION SHEET Concession Serial No. A Page 21 of 21 K Form No Issued: 08/95 Revised 8/05 QSDC NO:Q5B-000 Section 10a Page 12 of 13

13 APPENDIX C Concession Corrective Action Report (Form No. Q7B-557) Concession Serial No. Concession Corrective Action Report Root Cause of Non-Conformance A1 Owner Corrective Actions EDC Close out A2 A3 A4 A5 Form No. Q7B-557 Issue 3 Submitted by Title Date A6 QSDC NO:Q5B-000 Section 10a Page 13 of 13