Can Boeing Ship a Lengthy-Time Period Approach to their 737 MAX Issues?

Dr. IJ Arora

Boeing is within the highlight once more with its 737 MAX planes, that have already had a deeply bothered historical past. Buyer center of attention (which is clause 5.1.2 of ISO 9001 and AS9100) turns out to were misplaced someplace.

I’ve learn a number of contemporary articles on those incidents in addition to Peter Robison’s ebook Flying Blind: The 737 MAX Tragedy and the Fall of Boeing, all of which level to a worsening scenario for Boeing. The general public belief of this nice American corporate, which has all the time been dedicated to top-class engineering and depended on merchandise, is converting from one among admire to one among warning. Vacationers are questioning, “Must I fly in a 737 MAX?”

Boeing and the aerospace {industry} normally have excessive requirements for high quality and product protection. On this article, I postulate whether or not an organization’s high quality control machine can ensure that not anything is going fallacious for patrons. Can it make certain perfection? If no longer, what are the choices—and why have one in any respect?

What took place and who’s accountable?

For the ones no longer acquainted with the 737 MAX incident in January, in a while after an Alaska Airways flight departed from Portland, Oregon, a cabin door panel blew off. As investigations are nonetheless ongoing the reasons have no longer but been totally decided. Boeing additionally had a tool factor at the 737 MAX, ensuing within the crash of a Lion Air flight in 2018 and an Ethiopian Airlines flight in 2019.

Right here in the US, the Federal Aviation Management (FAA) performs a vital function in offering laws to make sure flight protection, and likewise supplies oversight of plane producers, airports, and upkeep suppliers. On the subject of the Alaska Airways flight, it kind of feels that the FAA didn’t uphold its depended on function. The FAA’s a large number of assessments and balances, maximum of that are meant to concentrate on buyer protection, had been like aligning holes in slices of Swiss cheese. It’ll be fascinating to peer what adjustments this incident brings about on the FAA. On the other hand, can regulatory oversight ensure protection of flight?

The AS9100 same old, which is restricted to the aerospace {industry}, isn’t the brainchild of a unmarried entity, however fairly a collaborative effort pushed by means of two key gamers:

  1. The World Aerospace High quality Staff (IAQG). This global group brings in combination representatives from aviation, house, and protection firms around the Americas, Asia/Pacific, and Europe. They actively take part in growing, keeping up, and updating the AS9100 same old.
  2. Standardization organizations. Those our bodies, such because the Society of Automobile Engineers (SAE) within the Americas and the Ecu Affiliation of Aerospace Industries (now the AeroSpace and Defence Industries Affiliation of Europe), formally submit and distribute the usual.

You will need to word that AS9100 builds upon the root of the extra normal ISO 9001 high quality control machine same old. Whilst ISO 9001 lays the fundamental framework, the IAQG provides industry-specific necessities a very powerful for making sure protection and high quality within the aerospace area.

Along with the producer and the FAA, the landlord/lessor of the plane additionally performs a task in making sure the aircraft is correctly maintained. This comprises settling on a reliable upkeep supplier, hiring competent engineers, and having powerful processes in position. With such a lot of other stakeholders, can blame be attributed to only one when injuries occur? Moreover, must blame be the secret? Possibly no longer! You will need to word that the machine is applied to toughen every consumer and that each one stakeholders within the worth chain play their phase as effectively.

Audits, inspections, and control methods: Are those the answer?

In the back of each tragedy, casualty, and mishap is a series of comparable occasions. The instant suspect when these kind of vital screw ups happen are deficient inspection protocols, possibly even the feared “human error.” On the other hand, this can be the low-hanging fruit and a deeper dive would possibly establish different causal elements, akin to asking if the standard audit failed.

What’s the distinction between an audit and an inspection? Can they change every different or are inspections by myself sufficient? The straightforward resolution is not any! Each are wanted because of elementary variations in method. Audits take a look at the processes to make sure the control machine produces conforming services and products. An effective control machine should come with the next, to call a couple of:

  • It should be well-defined, beginning with the “as-is” state of the machine.
  • Dangers should be known (clause 6.1) according to the context of the group (clauses 4.1 and four.2).
  • A transparent definition of the product should be known.
  • Efficient audits and periodic evaluation should be undertaken by means of control.
  • Outsourced processes should be managed.

Inspections play the most important function by means of figuring out defects previous to unlock, thus protective no longer most effective the buyer/buyer/consumer/warfighter, and so forth., but in addition the recognition of the group itself. With that stated, inspections don’t give a contribution to power development as a result of they center of attention on fixes versus long-term answers. In impact, they don’t in reality upload worth for the reason that group has already incurred the price of generating the faulty phase or product. The creators of the Toyota Manufacturing Machine (i.e., lean) got here up with the Andon procedure to catch a defect as early within the procedure as imaginable as a way to repair it sooner than the issue went too a ways down the road.

Control methods aren’t only a choice of paperwork. To serve as correctly, they require dedication in any respect ranges of the group, together with height control offering the wanted assets. It takes time to construct a tradition of high quality wherein shortcuts are have shyed away from and there’s no worry of talking up. Buyer center of attention should no longer be compromised. As an example, unlock of conforming product must cross throughout the procedure particularly referred to as out by means of clause 8.6; any interference by means of height control to truncate this procedure would suggest the lack of buyer center of attention. Is that this an opportunity? Possibly, however the investigation should expose the reality. On this case of the Alaska Air incident each the Boeing consumers and Boeing as an organization have suffered. It’s my hope that investigators will establish all failed portions of the machine from every accountable birthday celebration. Those would possibly come with no longer most effective failed inspections, but in addition suboptimal processes. This may finally end up taking us again to an insufficient high quality control machine.

High quality control methods: Can they ship?

Given the above, can a correctly designed and well-audited control machine (supported by means of excellent inspection tactics to assist make certain conforming product) ensure that not anything is going fallacious with a company’s output? My opinion is that no person can ensure this utterly. On the other hand, possibility can indisputably be very much decreased when the entirety is applied effectively. This comprises the educational of team of workers, which correlates strongly to competence; sadly, that is ceaselessly the primary price range to get minimize when assets are scarce.

When high-visibility incidents like those happen, it can be forgotten that airplanes stay the statistically most secure mode of go back and forth on earth. That is essentially because of powerful high quality control methods, well-adopted regulatory frameworks, and common oversight. People play the most important function within the good fortune of the control machine, from the dedication on the height to the buy-in by means of the body of workers (clause 5 to clauses 7.1.3, 7.1.4, and 10.3). Taken in combination, this is helping create an atmosphere the place high quality can flourish inside the group.

Boeing could also be doing so much accurately, and but the consequences may well be unacceptable relying at the efficiency of outsourced processes (clauses 8.41/8.4.2/8.4.3). In spite of everything, the fuselages for the 737 MAX are made by means of Spirit AeroSystems Holdings Inc. Spirit AeroSystems is positioned in Wichita, Kansas; as soon as those fuselages are manufactured, they’re shipped by means of rail to Boeing’s facility in Renton, Washington. Due to this fact, no longer most effective is a significant part of the 737 MAX outsourced, however the delivery and preservation of product (clause 8.5.4) additionally may just give a contribution to the product’s nonconformity. General, Boeing stays chargeable for all the provide chain (clause 4.3), with their legal responsibility to “make certain conformity of its services and products and the enhancement of shopper delight.”

Even with a cast high quality control machine in position, this or identical screw ups can happen. There’s no technique to guarantee the general public of 100-percent acting (i.e., highest) output. The worry within the minds of air vacationers is legitimate and can stay so till an exhaustive root motive research of this factor is carried out and the ones root reasons are resolved. The present occasions beg the query: Did Boeing make stronger their control machine after the Ethiopian Airways 737 MAX crash? If that they had bent to the oars and long gone deep into their evaluation to discover and completely repair the holes of their control machine, this tournament would possibly by no means have happened. Floor corrections, or what some organizations name “repair -it” answers, most effective take away the indications. The foundation reasons should be addressed and resolved (clause 10.2.1). There aren’t any shortcuts to high quality.

In conclusion

It has taken years for air vacationers to really feel protected and unconcerned about air protection. I go back and forth so much the world over, and ceaselessly select an airline according to their carrier and luxury, however now I (in addition to the wider public, I might consider) want to imagine which plane will delivery us. This can be a new worry about product protection that has its genesis in Boeing no longer working its control machine successfully and shedding buyer center of attention. The worst is the erosion of public self assurance in federal oversight and its intent to stay the client protected.

I’ve spent my lifestyles learning identical complicated issues and main groups in serving to organizations in finding long-term sustainable answers. This calls for daring and dynamic management (clauses 5.3 and 5.1) for leaders to plot and enforce alternate. Appreciating and accepting dangers (i.e., protecting the client in center of attention) and transferring ahead is integral to true management. Ethics continues to be no longer a clause of ISO 9001 and AS9100, however moral management is ready doing the proper factor for all stakeholders.

In seminars at which I provide, I ceaselessly ask senior managers: “When you have a decision between following the process and/or doing the proper factor, what would you do as a pace-setter?” The solution—I’m hoping—is to do the proper factor always. However then, hope isn’t a plan. Air protection can’t be according to hope and religion. Boeing wishes the management to revamp their machine if they’re to carry the general public consider again for this nice American corporate.

Concerning the writer

Dr. IJ Arora, Ph.D., is the President and CEO of QMII. He serves as a workforce chief for consulting, advising, auditing, and coaching relating to control methods. He has carried out many lessons for the US Coast Guard and is a well-liked speaker at a number of universities and boards on control methods. Arora is a Grasp Mariner who holds a Ph.D., a grasp’s level, an MBA, and has a 34-year file of accomplishment within the army, mercantile marine, and civilian {industry}.

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AS9100 Lead Auditor Training: A blog about how to become a lead auditor

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Are you looking to take your auditing skills to the next level and become a lead auditor? If so, AS9100 lead auditor training may be just what you need. This comprehensive certification program is designed for professionals who want to specialize in aerospace quality management systems auditing. In this blog post, we'll explore what exactly AS9100 lead auditor training is, what it means to be a Lead Auditor in this industry, and the steps required to obtain this coveted certification. So buckle up and get ready for an exciting journey into the world of AS9100 lead auditor training!

What is AS9100 Lead Auditor Training?

AS9100 Lead Auditor Training is a quality management system standard specifically designed for the aerospace industry. It was created by the International Aerospace Quality Group (IAQG) to address the unique challenges faced by organizations in this field.

The AS9100 standard builds upon ISO 9001, but also includes additional requirements that are specific to the aerospace sector. These include things like product safety, configuration management, and risk management.

Implementing AS9100 lead auditor training can help organizations ensure that their products and services meet or exceed customer expectations, while also complying with regulatory requirements. It can also help them improve their operational efficiency and reduce costs through better processes and procedures.

Achieving AS9100 lead auditor training certification is a significant achievement for any organization operating in the aerospace industry. It demonstrates a commitment to quality excellence and provides assurance to customers that they are working with a trustworthy partner.

What is a Lead Auditor?

A Lead Auditor is a professional who has the expertise to conduct audits of management systems based on international standards. In the aerospace industry, AS9100 is the standard that specifies requirements for quality and safety management systems. A Lead Auditor plays a vital role in ensuring compliance with these standards.

To become a Lead Auditor, one must have extensive knowledge of the AS9100 standard and its requirements. They should possess advanced auditing skills and be able to lead an audit team effectively. Typically, individuals who aspire to become Lead Auditors undergo rigorous training programs to develop their competencies.

During an audit, a Lead Auditor evaluates whether an organization's processes conform to the requirements laid out by AS9100. They analyze data gathered during an audit to identify any process gaps or areas of non-conformance that need improvement.

The role requires excellent communication skills as they are responsible for reporting findings back to senior management or clients while making recommendations for corrective actions where necessary.

Becoming a certified Lead Auditor is essential in ensuring that organizations meet international standards and provide high-quality products or services while maintaining compliance with regulations in their respective industries.

The steps to become a AS9100 Lead Auditor

Becoming a Lead Auditor for AS9100 requires dedication and hard work. Here are the steps you need to take to become one:

1. Gain Knowledge: Before becoming an auditor, you should have knowledge of the AS9100 standard, its requirements, and underlying principles. You can gain this through training or experience.

2. Attend Training: To become a Lead Auditor for AS9100, you must attend an accredited training course that covers the standard's requirements and audit techniques.

3. Gain Experience: After completing your training, it is important to get practical experience in auditing processes related to aviation, space, and defense industries.

4. Become a Certified Internal Auditor: The next step towards becoming a Lead Auditor is to become certified as an internal auditor by demonstrating your understanding of the auditing process.

5. Apply for Certification: Once you have completed all necessary requirements including education/training hours and practical experience hours in auditing aviation/space/defense-related industries; submit your application for certification at any authorized body after passing required exams

These steps will help anyone who wishes to become an AS9100 Lead Auditor succeed in their pursuit while ensuring they meet all necessary qualifications along the way.

The benefits of becoming a AS9100 Lead Auditor

Becoming an AS9100 Lead Auditor comes with many benefits, both professionally and personally. First and foremost, lead auditors are highly sought after in the aerospace industry due to their expertise in quality management systems. This translates into a wider range of job opportunities and potentially higher salaries.

Moreover, by becoming a lead auditor, you develop strong analytical skills that will help you identify areas for improvement within organizations. You'll be able to provide valuable insights on how to optimize processes and improve efficiency.

Additionally, working as a lead auditor requires excellent communication skills since it involves conducting audits and providing feedback to stakeholders at all levels of the organization. This can help improve your overall communication abilities which is beneficial not only for work but also personal relationships.

Obtaining certification as an AS9100 Lead Auditor demonstrates your commitment to continuous learning and professional development. It's evidence that you strive towards being the best in your field which can further enhance your reputation among clients or employers alike.

There are numerous advantages associated with being an AS9100 Lead Auditor including career advancement opportunities, enhanced analytical skills, improved communication abilities as well as demonstrating one's dedication towards ongoing personal growth.

How to maintain your Lead Auditor certification

Maintaining your Lead Auditor certification is crucial to ensure that you are up-to-date with the latest industry standards and regulations. Here are some tips on how to maintain your certification:

Continued Education: One of the best ways to keep yourself up-to-date is by attending training programs, seminars, and conferences related to AS9100. This will help you gain a deeper understanding of the requirements and make sure that you're following them.

Professional Experience: Continuously working as a lead auditor helps you stay updated on all aspects of auditing procedures in your line of work. It also gives you an opportunity for continuous improvement while conducting audits.

Internal Auditing: You can offer internal auditing services within your organization or take part in them if there are any opportunities available. Internal auditing provides hands-on experience in various areas such as risk management, quality control systems, corrective actions etc., providing more value-added insights for future external audits.

Networking Opportunities: Connecting with other auditors within related industries can be beneficial for sharing knowledge and experiences which leads to new ideas about how best practices can be improved upon over time

By taking these steps towards maintaining their certification status, professionals demonstrate their commitment towards staying relevant in their profession while ensuring continued growth throughout their careers as professional auditors.

Conclusion

Becoming a lead auditor is a significant achievement in the quality management field, and obtaining AS9100 lead auditor training can help you reach your career goals. By following the steps outlined in this blog post, you can start on the path to becoming an expert in auditing aerospace organizations' quality management systems.

Remember that being a lead auditor requires extensive knowledge of industry standards, advanced auditing techniques, and excellent communication skills. Continuous learning and experience are necessary to maintain your certification as well.

If you're looking for professional development opportunities or seeking new career prospects within the aerospace industry, consider pursuing AS9100 Lead Auditor training today!

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Why AS9100 Lead Auditor Training is Essential for Aerospace Industry Success?

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Ready for takeoff? If you're looking to soar high in the aerospace industry, then As9100 Lead Auditor Training is a must-have. This specialized training program ensures that you have the skills and knowledge needed to navigate complex quality management systems and maintain compliance with industry standards. So buckle up and join us as we explore why As9100 Lead Auditor Training is essential for achieving success in this rapidly-evolving field. From boosting your career prospects to enhancing safety measures, get ready to discover all the ways this training can help you reach new heights!

Introduction to AS9100 Lead Auditor Training

AS9100 lead auditor training is essential for aerospace industry success because it provides the knowledge and skills necessary to effectively audit an organization's quality management system. The training covers all aspects of the AS9100 standard, including its requirements, structure, and implementation. Additionally, the course teaches participants how to plan and conduct audits in accordance with international standards.

Benefits of AS9100 Lead Auditor Training

AS9100 Lead Auditor training provides a number of benefits for those working in the aerospace industry. The training helps individuals to develop the skills and knowledge necessary to effectively audit an aerospace quality management system. Additionally, the training provides individuals with an understanding of the requirements of AS9100 and how to apply them to an aerospace organization. The training helps participants learn how to effectively communicate with auditees and understand their needs.

What is QMII?

As the aerospace industry grows and becomes more complex, the need for qualified lead auditors who can ensure compliance with quality management system (QMS) requirements becomes more important. QMII is a comprehensive lead auditor training course that covers all aspects of auditing a QMS. The course is designed to give participants the skills and knowledge necessary to audit a QMS in accordance with international standards. It covers topics such as how to plan and conduct an audit, how to report on findings, and how to follow up on corrective actions. After completing the course, participants will be able to confidently lead audits of aerospace suppliers and other organizations.

Advantages of QMII’s as9100 Lead Auditor Training

QMII’s as9100 Lead Auditor Training provides a number of advantages for those looking to improve their aerospace industry credentials. The course is designed to give participants the skills and knowledge necessary to become a lead auditor for the as9100 Quality Management System. The as9100 standard is the international quality management system standard specifically for the aerospace industry. Lead auditors are responsible for assessing an organization’s compliance with the requirements of the as9100 standard. They perform audits to ensure that an organization’s quality management system is effective and compliant with all relevant regulations. Lead auditors must have a detailed understanding of the as9100 standard and be able to identify non-conformities within an organization’s quality management system. QMII’s as9100 Lead Auditor Training course is conducted over five days and includes both classroom-based instruction and practical hands-on experience. The course covers all aspects of the as9100 standard and provides participants with the skills and knowledge necessary to successfully audit an organization’s compliance with the standard. The advantages of QMII’s as9100 Lead Auditor Training include: - Detailed coverage of the requirements of the as9100 standard - Practical experience in conducting audits - Opportunity to assess an organization’s compliance with the as9100 standard - Skills and knowledge necessary to become a lead auditor for the as9100 Quality

10 Crucial Advantages of As9100 Lead Auditor Training

There are several reasons why As9100 lead auditor training is essential for aerospace industry success. First and foremost, it provides individuals with the knowledge and skills necessary to effectively audit an aerospace organization. The training covers all aspects of the AS9100 standard, including its requirements, methods, and tools. Additionally, the training covers how to properly plan and conduct an audit, as well as how to report on findings. Second, As9100 lead auditor training helps to ensure that individuals possess the necessary skills to assess an organization's compliance with the AS9100 standard. In particular, the training covers how to identify non-conformities and make recommendations for corrective action. Additionally, the training helps participants understand the importance of maintaining objectivity during an audit and ensuring that their personal biases do not influence their judgments. Third, As9100 lead auditor training helps participants develop a deep understanding of the aerospace industry and its unique challenges. The training covers topics such as aviation regulations, quality management systems, aircraft design and manufacturing processes, and supply chain management. Additionally, the training helps participants gain an appreciation for the impact that their work can have on safety-critical systems. Fourth, As9100 lead auditor training prepares individuals to take on more responsibility within their organizations. The training helps participants understand what is expected of them in terms of conducting audits and reporting on findings. Additionally, the training equips individuals with the skills needed to provide leadership and direction to other members of their audit teams

Conclusion

AS9100 lead auditor training is an essential part of the aerospace industry’s success. It helps ensure that all operations within the industry are conducted safely and in accordance with international standards for quality management. Not only does this provide confidence to customers in the quality of products produced, but it also ensures that the aerospace industry remains competitive on a global scale. By taking advantage of as9100 lead auditor training, aerospace professionals can ensure their organization’s success and stay ahead of their competition.

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AS 9100 – Getting Employee Engagement in the System

AS 9100 aerospace quality management systems enable organizations a framework for using a process-based approach to meeting customer requirements. AS 9100 in clause 5.1.1h requires the leadership to show their commitment to the system by “engaging, directing, and supporting persons to contribute to the effectiveness of the quality management system.” Further clause 7.3 asks organizations to ensure that those working under their control are aware of their contributions to the effectiveness of the system, to product safety, product conformity and the need for ethical behavior. Many organizations struggle to get employee buy-in to the system. Some organizations reward best teams and performers but how do we get intrinsic involvement and buy-in from all. This article discusses some steps that companies can take to encourage intrinsic employee involvement in the system. 

Setting Challenging Objectives 

AS 9100 asks organizations to set objectives at relevant functions, levels and processes. When setting objectives, QMII encourages organizations to set objectives for each process/procedure. These can further be broken down into smaller goals for individual process team members. The objectives must flow from the policy so in doing their work to achieve the goals it is clear to the employee on how they impact the customer. The objectives when too easy do not encourage improvement or motivate the workforce. When too challenging affect morale as the goals/objectives are never reached. Review the objectives at periodic intervals to monitor progress and readjust as necessary.  

Management Involvement 

The workforce is more willing to pitch in when they see the leader pitching in. This must be something they do often rather than once in a while. The workforce must get representation at meetings on quality. This may be in the form of their suggestions for improvement being presented to the management at the management review and then receiving feedback on their suggestions rather than never knowing what happened. Management may choose to present to the workforce on a monthly or quarterly basis on the state of the system so the workforce knows where the organization stands and where it is heading. The workforce must feel like the part of a team and a valued team member. Only then will they willingly contribute. 

Customer Focus 

Often each worker may not know who the end customer is or get to see the end product in use and how the product benefits customers and their business and further end users. Organizations must make known to the users who the end customer is, share positive feedback received from customers, accolades received by the company and perhaps even arrange to see the end product in use.  

Personal Development 

Investing in personnel is a great way for an organization to show the workforce that they care. That you are willing to invest in them because they invest so much in what they do. Consider AS 9100 training for your workforce. It will also better help them understand why they do what they do. QMII offers a number of different training formats for AS 9100, including an overview, internal auditor and lead auditor format.  

 

Why pursue AS9100 certification

What is AS9100?

In the aerospace industry, a small error in the supply chain can have catastrophic consequences.  AS9100 was developed to manage the extensive global supply chain of aerospace manufacturers and to ensure that each is implementing an effective quality management system.  AS9100 is based on the framework of ISO 9001 and follows the same high-level structure.  A company conforming to the requirements of AS9100 also meets the requirements of ISO 9001.

AS9100 certification  provides third party validation of the processes an organization has put in place to manage the quality of the product/service they deliver. It can also provide confidence to customers that the organization adheres to the highest standards of quality and safety.

Is AS9100 certification mandatory?

AS9100 and ISO 9001 allow organizations to self-declare conformance.  However, if you are looking to do business in the aerospace industry AS9100 certification is practically mandatory.

AS9100 and ISO 9001 allow organizations to self-declare conformance.  However, if you are looking to do business in the aerospace industry AS9100 certification is practically mandatory.  For a company to be listed on the OASIS supplier database, it will need to have AS9100 certification.  Companies not registered with the OASIS supplier database will have trouble doing any business in the aerospace sector. 

Is it worth it?   

AS9100 certification  comes at a cost, of course.  There are recurring costs as recertification occurs every 3 years and there are annual surveillance audits conducted in the intermediate years.  Developing and maintaining the system will require resources including training time and time spent on improving processes. 

In addition to being listed with OASIS, meeting the requirements of ISO 9001 and AS9100 provides other benefits.  One of these is the creation of feedback loops for communicating and implementing opportunities for improvement.  Another is that it ensures non-conformities are addressed and that effective corrective action is taken.  In addition, it ensures that management remains more involved in the system and that quality is integral to the management system. 

What about audits? 

While AS9100 certification may reduce the possibility or frequency of a supplier audit, it does not imply that an organization will not get audited.  Supplier audits look at an organization’s compliance to supplier requirements as well as the AS9100 standard.  Certification to AS9100 also does not reduce the internal checks required by the company.  AS9100 certification audits will not go to the same depths that internal audits can, which is why internal audits are vital to the success of the system. 

An organization looking to do business in the aerospace industry will need to consider AS9100 certification when implementing a system.  Care must be taken in the system implementation not to use a one size fits all template and to make the effort to build a strong management system that will deliver benefits beyond just the certificate on the wall. 

Who should do the PEAR in AS9110

AS9110 Process Effectiveness Assessment Reports are used to identify the effectiveness of a process. PEAR was developed to allow audit personnel to systematically evaluate the effectiveness of a process as performed by the organization. It takes the inputs, outputs, actual steps of the process and recourses and controls in account.

Turtle diagrams are often sued to depict PEARs. The PEARs are a tool to be completed by the auditor in their assessment of the AS9110 system. It is however beneficial to have the process owner complete one as this gives the process owner a good indication of how well their process is working and where, if any, improvements may be made. Often to ease the process for the auditor the internal quality manager will complete the PEARs and keep them prepared for the auditors. It is however not the role of the quality manager to do this and nor does it enable any improvement.

AS9110 asks organizations to conduct internal audits to assess the effectiveness of the processes and system. However, QMII at times finds that the audits are limited to determining conformity only. The PEARs come in handy here by enable a process-based audits and allows for due diligence to be done by the auditor. To identity that the resources and controls assigned are adequate to ensure that conforming inputs deliver conforming outputs while meeting the effectiveness goals of the organization through monitoring and measurement.

So how many PEARs do we need? The organization will need one for every key process it identifies within it system and this can run up to 15 to 20 at times depending on the size of the organization and perhaps even more. There is no preset minimal number of PEAR’s required from an audit. When an auditor is assessing effectiveness, the auditor is essentially measuring how well the organization does this. What metrics are they monitoring to know whether they are meeting objectives or not. What did they take into consideration in setting their objectives e.g., customer requirements, legal requirements etc.

The organization is then scored by the AS9110 auditor based on the guidelines provided in AS9101. AS9101 provides a Process Effectiveness Matrix that scores the organization across two axes. The first being process realization – the extent to which planned activities are realized and the second – process results – the extent to which planned results are achieved. Based on this scoring the lowest grade sates “(a) The process is not defined, implemented, and planned activities not realized, and (b) The process is not delivering the planned results and appropriate action is not being taken.” The highest score equates to “(a) The process is defined, implemented, and planned activities fully realized, and (b) The process is delivering the planned results.

How AS9100 prevent airline accidents

It is said that air travel is statistically one of the safest modes of transportation. The flights that do not land well or go missing make the news more than the 1000’s of those that complete a safe flight. Checklists used in the aviation industry are infamous for how well they assist pilots deal with disasters. However, a lot is to be said for the plane itself, which is built to stringent quality requirements, down to the last rivet. Many aerospace parts manufacturers are certified for AS9100. So, what is AS9100?
It is an internationally accepted standard that defines the requirements for a quality management system for companies. It is built on the foundation of ISO 9001, another globally recognized quality standard. It builds the framework for organizations to identify risks at all stages of the production or service realizations process. The standard sets the baseline for quality and once implemented within an organization is assessed and certified by independent accreditation bodies. So, a part produced by an AS9100 certified organization in India, Brazil or elsewhere will meet the basic quality requirements.
What is AS9100 prescribing that companies do to achieve this? As9100 is not prescriptive in its requirements. It defines the framework, and each company must then interpret the requirements as they best apply to what they do. The leadership of the organization must remain involved and is accountable for the effectiveness of the system. The systems are influenced by regulatory requirements, customer requirements and other business requirements as from various stakeholders. What is AS9100 requirements with respect to control of outsourced processes.
Organizations must control outsourced processes and remain responsible for the output of the process. Based on the performance of the vendor of the criticality of the parts etc., the type and extent of control may vary. AS9100 also requires organizations to determine the competence of personnel needed and then to take steps to achieve this competence. As9100 quality requirements must be flowed down to all suppliers in the supply chain and supply chain risks are to be considered and mitigated as appropriate.
What is AS9100 requirements for audits. External certification audits are conducted on a three-year cycle with annual surveillance audits in the intermediate years. Internal audit frequency is determined and based on the organization needs and the auditors used to conduct the audits must be competent. To achieve this competence, they should compete a certified AS9100 lead auditor training. QMII offers a PROBITAS Authentication lead auditor training in both virtual and on-site format. These stringent quality requirements in the supply chain as advocated by AS9100 help ensure planes meet the highest safety and quality requirements. Thus helping to reduce accidents.

AS9100-Risk-Based Thinking in the Airline industry – It’s about time.

The airline industry statistically has one of the best safest records. AS9100 defines the framework for a quality management system for aerospace parts manufacturers across the globe. Over the past decade there have been several airline accidents however, that have brought the safety of airlines to the forefront. In a most recent case of the Boeing 737-max a software glitch was identified as the cause. As investigations proceed the general consensus is that this glitch should have been previously identified.

Risk generally is associated with ‘uncertainty’ or ‘negativity’. This changed with ISO 9001:2015 and the onset of risk-based thinking that now asks companies to consider the opportunities for improvement that may arise out of taking a ‘calculated’ risk. Further in AS9100, that is built on ISO 9001, there are requirements for consideration of strategic risks and operational risks and the need to take action to address each. The impact of coronavirus or a similar pandemic is a great example of a strategic risk that can affect business continuity.

Risk-based thinking in the AS9100 standard promotes customer focus within an organization. While risk-based thinking has been inherent in previous versions of the standard with preventive action, the new standards address risk at each stage of the PDCA cycle thus enabling the entire As9100 management system at each stage as a preventive tool.

The aerospace and automotive industry are leaders in the implementation of Failure mode and effects Analysis (FMEA) and the Plan-Do-Check-Act Cycle (PDCA) of process management.  Originally adopted by the military in the 1950’s, FMEA later was embraced by the auto and aerospace industries.  The FMEA process identifies risks that can then be addressed using mistake proofing and problem solving with a team approach.  FMEA can be used for either product or process. When used properly it can be a very effective at addressing risks. FMEA is a great core tool that can be applied to address the AS9100 clause 8.1.1 operational risk requirements.

AS9100 asks top management to take accountability for the quality of products and services produced by their organization; keeping a customer focus at the core of all they do.  The influence of end users, customers and the companies marketing department on the product’s design needs to be constantly reviewed. At each stage of the requirements gathering, design & development and manufacturing stages of the AS9100 system there are potential risks. As such doing a single FMEA may not be sufficient but may require a review of the FMEA at periodic intervals as a change in inputs to the process/product may change the associated risks or identify new ones.

Management wants to encourage continuous improvement and innovative recommendations by all stakeholders, but changes must be reviewed.  Whenever a change is made to a AS9100 certified product or service, that change should follow the PDCA Cycle approach, the same way it was done when the product was first introduced.  This will reduce the number of recalls, and the risk of injuries to end users of the products.

A single non-conforming product that goes out of the organization into the market results in an intangible loss for no value can be put on the loss of reputation. It only takes a single incident! Starting with risk appreciation at the Plan stage of the PDCA cycle and then throughout the rest of the cycle, with a focus on customer satisfaction, will help the aerospace industry improve by preventing non-conformities before they occur as well as hopefully, improve their As9100 certified products.