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QA Production Certificate Requirements Panel 4: Manufacturing and Production Quality Assurance
Presented byMatthias Knüwer
NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
Content
• Airframe production overview
• Airbus production organisation against EASA Part 21 subpart G
• Manufacturing processes against CS25.605 and quality Assurance / Qualification
• Quality control management
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September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
Airframe production overview
•From sheet...
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September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
Stretchformed and chemically milled aluminum sheet for fuselage skin
Rollbended aluminum sheet for stringers and frames
© AIRBUS Operations GmbH. All rights reserved.
Airframe production overview
•...to panel and fuselage section...
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September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
Upper panel Cockpit section
Forward Fuselage section
© AIRBUS Operations GmbH. All rights reserved.
Airframe production overview
•...to aircraft...
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September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
Production Organisation Approval (POA)
The Quality System controls and improves each element in the system …… to ensure:
• the Customer’s needs are continuously satisfied
• the regulations are continuously satisfied
• the complete production process is continually improved
• the product itself is continually improved
Machines
Manpower
Methods
Milieu
Materials
Part 21 subpart G rule 1: the company must show that they have set up and can maintain a Quality System
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September 21st / 22nd, 2011
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NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
Production Organisation Approval (POA)
When the Competent Authority is satisfied that the rules in the Part 21 subpart G have been applied, they grant the company a Production Organisation Approval (POA)
Part 21POA
To keep their POA, the company must continue to demonstrate to the Competent Authority that they apply the rules in Part 21 subpart G
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September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
Procedures
Instructions
© AIRBUS Operations GmbH. All rights reserved.
Airbus Process Instruction (AIPI):Describes and defines the parameters of a manufacturing process on working level.
Airbus Process Specification (AIPS):Describes the engineering requirements of
a manufacturing process and sets the “Key Characteristics”
Airbus Procedure (AP)Description of
principles and rules: The way of working
September 21st / 22nd, 2011
Manufacturing Process according to CS25.605: Requirement and Implementation
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Leve
l of d
etai
l
AuthorityRequirement definition
AuthorityRequirement definition
AirbusAircraft
Certification Document (ACD)
© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011
Qualification of Manufacturing Processes
• Subject of Qualification is a couple consisting of:• Manufacturing Process• Manufacturing Shop
• The AIPS/AIPI-development and general process qualification is done at an “Airbus Reference Manufacturing Shop”.
• Depending on the complexity of the process, the full qualification is repeated for each new shop or compliance is shown by First Article Inspection (FAI).
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NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011
Qualification of Manufacturing Processes
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Qualification Project Sheet (QPS)
Qualification Test Plan (QTP)
Qualification Test Report (QTR)
Qualification Compliance sheet (QCS)
Tim
e
AIPS / AIPI generated
Airbus need, development of a process
NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
Airbus Quality System relies on 7 main processes:• Set the Standards & Document them
All activities ensuring that all Quality Management System components are in place.
• Perform Measures: Identification, definition, production, record, analysis, review of process / product performance indicators.
• Perform Audit & Surveillance:Preparation and deployment of internal and external audit and surveillance activities.
• Manage Design non-conformance: Notify, analyze, classify, correct the non conformance. Identify preventive actions.
• Manage Manufacturing non-conformance: Notify and solve a non-conformance during production. Identify preventive actions.
• Perform Action Management, Review & Improvement: Analyse potential risks, identify and deploy preventive actions.
• Manage conformity & attestation: Ensure that parts, constituent assembly and aircraft are conform to airworthiness requirements.
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© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011NTSB Airplane Fuselage Structural Integrity Forum
Quality Control Management (inQuality Control Management (in--house or vendor) house or vendor)
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The main actors in the concession process are:Manufacturing (Originator) Airbus, Industrial Partners, SuppliersDesign Office Design and Stress or Specialist (Airworthiness, ..) Final Quality
Aircraft Delivery Official distribution
Request for ConcessionManufacturingAirbus Industrial PartnersSuppliers
Assessment and DecisionDesign OfficeDesign and Stress Specialist defines corrective action if needed.
Final Quality CheckQuality
© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011
Thank you!
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NTSB Airplane Fuselage Structural Integrity Forum
© AIRBUS Operations GmbH. All rights reserved.
September 21st / 22nd, 2011
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations GmbH. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations GmbH. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations GmbH will be pleased to explain the basis thereof.AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
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NTSB Airplane Fuselage Structural Integrity Forum