Aerospace MRO Supplier Quality Supplier Quality Assurance Requirements MRO1001 Rolls-Royce plc 2012 Page 1 of 7
Table of contents 1 Purpose 2 2 SABRe Scope and Applicability 2 3 Definitions 2 4 Forms and form templates 3 5 Requirements 3 6 tice to Suppliers 3 Change History 4 1. Purpose The purpose of MRO1001 and the applicable SABRe processes are to flow down to suppliers Rolls-Royce Aerospace Maintenance Repair Organisation quality assurance requirements and is available to view and download from the Rolls-Royce Global Supplier Portal (GSP) https://suppliers.rolls-royce.com Rolls- Royce Aerospace Maintenance Repair Organisations (MRO) MRO1001 and the applicable SABRe (Edition 2) processes are the supplier facing elements of the Rolls- Royce Aerospace Maintenance Repair Organisations Quality Management System (QMS) MRO1001 and supporting Compliance Requirements documents satisfy the minimum supplier quality requirements as mandated by Rolls-Royce Aerospace MRO MRO1001 and supporting Compliance Requirements documents take precedence and shall be used in conjunction with SABRe (Edition 2) 2. SABRe Scope and Applicability SABRe is applicable to all suppliers or partners who supply product related to Rolls-Royce contracts / purchase orders, when specified in said contracts / purchase orders. SABRe is the supplier-facing element of the Rolls-Royce Management System An extension of the Rolls- Royce Quality Management System. The purpose of SABRe is to formally communicate Rolls-Royce requirements and expectations to the global supply chain. It is the vehicle through which Rolls-Royce executes its corporate governance in the context of regulating its supply chain. When referenced in this document the name Rolls-Royce refers to Rolls-Royce Aerospace MRO This document covers Aerospace MRO product for: - o Engine/ Module Repair Suppliers o Line Maintenance Suppliers o Storage Locations (Engines and Components) o Component and Unit Repair The SABRe requirements are split into 3 Chapters A, B & C o Chapter A o Chapter B General Requirements Modelled upon the structure of ISO9001 (clause titles 4 to 8) and shows the additional general requirements and expectations of Rolls-Royce Rolls-Royce 2016 Page 2 of 7 Issue 2
Product and Production Process Requirements Embodies the concepts of error prevention and continual improvement that will be used to Build in Quality into the Operational processes as contrasted with error detection and is applicable as follows: New Product Introduction (NPI) Product Introduction (PI) Suppliers who currently supply product o Chapter C Production Product Approval Process Enables a supplier to obtain production product approval from the customer Has commonality with AIAG s PPAP (Automotive Industry Action Group s Production Part Approval Process) but differences exist given the distinctive requirements of Rolls-Royce and is applicable as follows: New Product Introduction (NPI) Product Introduction (PI) When requested by the customer. o Applicability for section A & B will be dependent upon the type of MRO Engine Repair Service provided to Rolls-Royce and the specific Audit Requirements document shall be applied See Compliance Requirements o Chapter C requirements are currently t Applicable for MRO Suppliers with the exception of Component and Unit Repair suppliers where a deployment matrix is in place Information marked NOTE is for guidance in understanding or clarifying the associated requirement. 3. Definitions 3.1 SABRe Definitions Refer to SABRe definitions for additional information. This document is available to view and download from the Rolls-Royce Global Supplier Portal (GSP), SABRe Supplier Management System Requirements Reference documents https://suppliers.rolls-royce.com 3.2 Meeting the intent of SABRe Guidance material is defined within Briefs and Guidance of the SABRe Supplier Management System Requirements A1.3 - Control of Rolls-Royce documents The supplier shall have a procedure which includes the controls needed for documents: For approval of Review and update process is traceable and controlled Report incomplete and ambiguous technical data External documents are identified and their distribution controlled Relevant versions of applicable documents are available at points of use Have controls to ditribution of documents to their suppliers A3.1 Training and competence Evidence personnel are trained and competent with on-going competence assessments B1.1 Project Management A launch plan shall be available for New Product Introduction (NPI) for new / first time repair activity, a significant Service Bulletin or a source / method change or re-activation following elapsed period of 2 years, or if specifically requested by Rolls-Royce. Rolls-Royce 2016 Page 3 of 7 Issue 2
B4.1 Production verification All product characteristics to be measured as per the approved maintenance definition and consistent with the work requested in the customer work order Monitoring / measuring equipment at final verification / inspection shall be independent of that used during rework / repair B4.4 First / Last Article inspection report (FAIR / LAIR) A LAIR is required prior to any source or method change. However, it is accepted that there may be circumstances where it is not possible to complete a LAIR (eg lack of repair arising s). In all such cases, the work will be considered N.P.I. Supplier shall have a working programme/ plan of engine/ module FAI and shall include Measurement System Analysis where applicable. Refer to self assessment guidelines for different FAI requirements for Engine/ Module repair services. 3.3 Programmes of Work Deployed A4.8 Foreign Object Debris (FOD) Incorporation of the intent of WI SP 3-2(A), Foreign object damage/foreign object debris (FOD) prevention including the FOD Programme Assesment Control of C-Class Parts Build Processes: C-class/ low cost parts (including Slave Parts) are provided to the fitter in the exact quantities required and confirmation that the correct numbers have been received is a stampable operation. A visual indicator is used so that the fitter can easily verify if the correct parts have been delivered, prior to commencing the maintenance task. This visual indicator should include a part number and reference critical any part dimensions. Check where the fitter finds himself with too many or too few C-class parts, there should be a process to verify that the right quantities have actually been fitted or to make a risk assessment about shortage or surplus. There should also be a reconciliation process in place. Strip Processes: A process shall exists to control the removal of C Class parts, ensuring that all parts are accounted for and stored or recorded for replacement as needed. Confirmation that the correct number of parts is removed and is a stampable operation. Removal of Slave Parts: A process shall exist to confirm that all slave parts have been removed from the engine in the correct quantities. Confirmation that the correct number of parts is removed is a stampable operation. The supplier shall not hold C Class line side stock and must be stored remote from the site of use in a controlled storage area that formally records and books out any withdrawals under a formal inventory control system. Effectiveness of the process shall be monitored, ensuring that where mandatory items are breached; there shall be an investigation to verifiy the failure leading to the event. A5.7 Corrective Action Eight Disiplines (8D) - As part of our Continuous Improvement activities we require ourselves (Rolls- Royce) and suppliers to raise the standard of problem solving to prevent the recurrence of quality issues. All suppliers within the Rolls-Royce Aerospace supply chain are required to improve their problem solving capability. B3.8 Identification, traceability and serialisation Prior to the release of product all requirements of the mod dec have been completed and verified, including electronically updating the mod dec to confirm that the modifications have been incorporated during this shop visit. For large assemblies a sample of detail parts should be reviewed. Control of C-Class Parts o C-class/ low cost parts are to be provided to the fitter in the exact quantities required to rebuild Rolls-Royce 2016 Page 4 of 7 Issue 2
the module / engine. o If the fitter finds themselves with too many or too few C-class parts, there should be a process to verify that the right quantity has actually been fitted or to make a risk assessment about shortage or surplus. There should also be a reconciliation process in place. Discretionary o C-class/ low cost parts are provided in a fishing tackle box or other container that makes it clear when the right parts are not present or are in the wrong quantity. o Where the fitter finds themselves with too many or too few C-class/ low cost parts, a process is to exist to identify the root cause for this and prevent reoccurance. 4. Forms and form templates Forms and guidance documents are available to view and download from the Rolls-Royce Global Supplier Portal (GSP) https://suppliers.rolls-royce.com Rolls-Royce Aerospace Maintenance Repair Organisation Suppliers FORMS refer to the forms that shall be used in accordance with the relevant section of this document FORM template refers to available templates that can be used in accordance with the relevant section of this document. However, the supplier s own form may be used when shown to be similar / equivalent. 5. Requirements See Aerospace MRO SABRe Approval Process (Click on Hyperlink) MRO SABRe Approval Process Quality & Capability Supplier Rolls-Royce Supplier Capability Required Existing Supplier with SABRe Approval? Is it to Maintain Approval Audit? Supplier Completes SABRe 2 Self Assessment & Returns to Rolls- Royce Inteligence Is Self- Assessment Completion Satisfactory? Inteligence n- Conformity Reports Specific Quality Plans MRO Quality & Capability identifies Performance & Contacts MRO Quality & Capability performs a Site Visit Review at the Supplier Manage n- Conformance / Plan Satisfactory? Selected Supplier t Sutable Supplier to be used in the future? Work with Supplier to Develop Capability Supplier SABRe Approved in Accordance with the Approval Letter Vendor SAP profile amended / created to reflect Approval status. Approved Maintenance Centre or SABRe Approved Work with Supplier to Develop Capability to World Class Performance MRO Quality & Capability identifies Performance & Contacts for Supplier Perform the Full Audit at Supplier (SABRe, Regulatory, Special Process) Satisfactory? Work with Supplier to Develop Capability Confirmation of actions completed? Escalation Letter raised and submitted to Service Operations and Project Quality Executive SABRe Approval Granted / Updated Rolls-Royce 2016 Page 5 of 7 Issue 2
5.1 Self-Assessment for New Suppliers or Suppliers extending their existing workscope capability eg workscope increased from Engine Overhaul to include Component Repair; The Self Assessment tool has been developed to provide an initial view of the level of supplier compliance to SABRe (Edition 2) The Self Assessment will be carried out by the supplier using SABRe (Edition 2) and the appropriate Compliance Requirements and will always be followed up by a review with RR which may require a site visit prior to the full audit depending on the Self-Assessment response Use the Self-Assessment template for your business A full audit shall be conducted by Rolls-Royce at the Suppliers facility in accordance with 5.2 below 5.2 Existing Suppliers A full audit may be conducted by Rolls-Royce covering the scope of existing capability dependent upon a risk assessment The critieria and applicability of the audit will be against the relevant Compliance Requirements for your business. The gaps identified shall be closed within the established timescales set by Rolls-Royce either through the non-conformance closure process or through an approved quality plan. 5.3 n Destructive Testing (NDT) Inspection Operations For all NDT inspection operations associated with component repair (except visual and NDT inspections during the sentencing activity following engine disassembly), reject rates shall be monitored. Any change in reject rates from the established norm may indicate that an unexpected change in the repair process has occurred that could affect component integrity. An investigation shall be undertaken to establish the cause of the increase, and a review of all other parts that could have been similarly affected shall be carried out. Measures shall be taken to restore process capability. Whilst the investigation is ongoing and until process capability has been restored, the risk of missing any defects by NDT must be mitigated. This is to be achieved by implementing the following on all parts deemed to be at risk: a) Applicable NDT inspectors shall be made aware of the problem, what to look out for, and where to look for the problem. b) The applicable NDT technique instruction shall be revised to instruct 'Directed Inspection' in the area of interest/concern. c) 100% double inspection/scrutiny shall be performed (i.e., over checking by a second inspector). These risk mitigation actions must remain in place until process capability has been restored. The same risk mitigation actions also must be applied when the repair process is known to generate levels of unacceptable defects that are a product of process and therefore represent an increased risk. Annual maintenance Review: Personnel who operate NDT equipment and/or accept production hardware shall be subject to an annual assessment of NDT inspection performance. The defect finding rates for individual NDT personnel who accept production hardware shall be continuously monitored and checked as part of this annual maintenance review. The defect finding rate is the number of instances that a defect indication is reported by an inspector per NDT method over a period of time, i.e., per week or month. The finding rate should be monitored over time. The results of any investigation must be reported to the Rolls-Royce Global Repair Services (GRS) Laboratory. Rolls-Royce 2016 Page 6 of 7 Issue 2
6. tice to Suppliers This is a process used by Rolls-Royce to communicate information to the global supply chain network. tice to Supplier documents should be viewed regularly and if applicable to your business with Rolls-Royce, they must be actioned accordingly. The Supplier shall have a review process in place to access the tices to Suppliers (NTS) portal at a frequency of minimum 2 weeks. Change History Revision Date Description of Change Approved by Issue 1 February 2014 Initial Issue for Aerospace MRO Requirements Issue 2 February 2016 Section 3 o Clarified where the Reference documents are located within the GSP o Added reference; Guidance material is defined within Briefs and Guidance of the SABRe Supplier Management System Requirements o Added 3.2 Meeting the intent of SABRe and 3.3 Programmes of Work Deployed within section 3 A1.3 - Control of Rolls-Royce documents A3.1 Training and competence B1.1 Project Management B4.1 Production verification B4.4 First / Last Article inspection report (FAIR / LAIR) o Added, 3.3 Programmes of Work Deployed A4.8 Foreign Object Debris (FOD) Control of C-Class Parts A5.7 Corrective Action B3.8: Identification, traceability and serialization Section 5 o Updated the MRO SABRe Approval Process diagram o Added into Section 5- Requirements; 5.3 n Destructive Testing (NDT) Inspection Operations Narinder Singh Rolls-Royce Stephen Brown Rolls-Royce Document update policy This document may be updated periodically. Amendments will be shown as an update from one revision number to a higher revision number (e.g. revision 1 to revision 2). The content of the higher revision are the latest requirements. Rolls-Royce 2016 Page 7 of 7 Issue 2