una società finmeccanica doc. qfra/04p.128/a9 rev. 3 dated :...

Una Società Finmeccanica

Doc. QFRA/04P.128/A9 Rev. 3 Dated : May 06

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THE CONTENT OF THIS DOCUMENT IS THE PROPERTY OF ALENIA AERONAUTICA S.p.A. THIS DOCUMENT IS SUPPLIED IN CONFIDENCE AND COMMERCIAL SECURITY ON ITS CONTENTS MUST BE MAINTAINED. IT MUST NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SUPPLIED NOR THE INFORMATION CONTAINED IN IT MAY BE DISCLOSED TO UNAUTHORIZED PERSONS. IT MAY NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT PERMISSION IN WRITING FROM ALENIA AERONAUTICA S.p.A.



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MODIFICATION DESCRIPTION

ISSUE DATE MODIFICATION DESCRIPTION APPROVAL

------- April 2004 First Release – Preliminary issue See Cover Page

Rev. 1 June 2004 Quality Requirements compliant with IAY G05 C See cover page

Rev. 2 January 2006 Added reference to AP 2190 Module 3 Removed reference to QPRA/03.099

Rev. 3 May 2006

Added “Quality Gates” description in section 8.2.4

Changed reference SMGN/04/025 to QFRA/06P021



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0. INDEX 1 Scope 2 Application 3 Normative reference / General

3.1 Normative reference 3.2 General 3.2.2 General Principles

4 Quality management system 4.2.1 General 4.2.3 Control of documents 4.2.4 Control of records

5 Management responsibility 6 Resource management 7 Product realization

7.3 Design and development 7.4 Purchasing

7.5.1 Control of production and service provision 7.5.2 Validation of processes for production and service provision

7.6 Control of monitoring and measuring devices 8.2.2 Internal audit 8.2.4 Monitoring and measurement of product

8.2.4.1 Inspection documentation 8.2.4.2 First article inspection

In this document, only those paragraphs of IAY G05 which present additional or special emphasized requirements are reported.



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1. SCOPE

This document defines the general quality system requirements for Suppliers involved in the A380 program - Airbus Germany W.P.’s. These requirements are to be regarded as additional to quality system requirements stated in Alenia External Procedure IAY G05. Further others product quality requirements shall be included into Work Package technical specifications.

2. APPLICATION

This document is applicable for the following aircraft work package activities subcontracted by Alenia: - design and manufacturing - design - manufacturing with material purchasing - manufacturing without material purchasing - industrialization

therefore, this document is applicable to Suppliers classified as one of the following Alenia Qualification Classes according to IAY G05: C1 – C2 – C3 – D1 – H1 – H2 (For the paragraph applicability refer to paragraph 3.2.2.6 of IAY G05). In this document, only those paragraphs of IAY G05 which present additional or special emphasized requirements are reported. 3. Normative reference / General 3.1 Normative reference The applicable documents are the followings at the most recent edition: INTERNATIONAL STANDARDS - AEROSPACE SERIES EN 9100/AS 9100 Aerospace series – Quality management systems – Requirements (based on ISO

9001:2000) and Quality systems – Model for quality assurance in design, development, production, installation and servicing (based on ISO 9001:1994)

EN 9102/AS 9102 Aerospace series – Qualty systems – First Article Inspection EN 9103/AS 9103 Aerospace series – Quality systems – Variation Management of key characteristics



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EN 9130/AS 9130 Aerospace series – Quality System – Record retention EN 9131/AS 9131 Aerospace series – Quality System – Non Conformance documentation INTERNATIONAL STANDARDS - QUALITY MANAGEMENT SYSTEMS ISO 9001:2000 Quality Management Systems – Requirements ISO 9000 Quality Management Systems – Fundamentals and Vocabulary ALENIA DOCUMENTS IAY G05 C Quality Management System Requirements for Suppliers IAE G 01 Engineering Off-Load Activity M123-01 Alenia Tooling Manual QFRA/06P.021 Linee Guida Per Sub-Fornitori Verticalizzati Che Intendono Utilizzare La D. C. A./ R. P. T.

Rilasciata/Implementata Da Alenia Aeronautica Verso I Propri Fornitori Di Grezzi E Standard

AIRBUS GERMANY DOCUMENTS AP 2190 - Module 3 General Requirements for Aerostructure and Material Suppliers - Quality General

Requirements 3.2 GENERAL 3.2.2 General Principles In addition: The program activities are subjected to Alenia, Airbus Germany and Airworthiness Authority surveillance. The supplier shall assure Right of access for: • Alenia personnel • Airbus Germany representative • Airworthiness Authority representative The Supplier and its sub-tier shall be available to be submitted to the scheduled and/or unscheduled Alenia/Airbus Germany/Authority audit activity, and/or to provide all quality records and technical information relating to the orders in progress necessary to exercising their surveillance actions within a reasonable time from the request. Special emphasis: The Supplier shall undergo to Alenia Qualification. Major points involved in the Alenia qualification process are: • products / supplier pair qualification • special processes qualification • re-qualification criteria



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The Supplier shall be able to meet Contract requirements, including quality system and any quality assurance requirements before starting production activities. In case of non compliance with contract requirements, an improvement / qualification plan will be issued by Supplier and agreed with Alenia. Note: the qualification and surveillance exercised by Alenia (audit, inspection, etc.) do not waive the Supplier’s responsibility as far as the products are concerned. 4. QUALITY MANAGEMENT SYSTEM 4.2.1 General Special emphasis: The Supplier shall prepare a Quality Assurance Plan (QAP) in accordance with Alenia form (IAY G05 attachment 1), with the objective to define and document how the requirements for quality will be met. The Quality Assurance Plan shall cover all products and processes and in particular CAD/CAM/CAI applied management system shall be described (if applicable to the work package) . 4.2.3 Control of documents In addition: When Alenia / Airbus Germany provide digital data used for design, production and/or inspection, the Supplier shall establish a data management system in accordance with Alenia / Airbus Germany requirements. Special emphasis: Documents and data can be in the form of any type of media, such as hard copy or electronic media. Supplier shall establish a process to ensure the timely review, distribution, implementation and maintenance of all authorized and released drawings, standards, specifications, planning and changes. The Supplier shall maintain a record of changes. When required documentation changes shall be coordinated with Alenia.



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4.2.4 Control of records In addition: All quality records shall be made available for review by Alenia/Airbus Germany/Regulatory Authorities as required. 5. MANAGEMENT RESPONSIBILITY Special emphasis: The A380 program organization chart shall be included in the Quality Assurance Plan and the responsibility of each function shall be indicated. In particular, the Program Quality Manager shall be indicated and shall have defined authority and organizational freedom to resolve matter pertaining to quality. 6. RESOURCE MANAGEMENT Special emphasis: The quality activity performed by an individual process performer, such as special processes operator, shall have procedures approved by Alenia / Airbus Germany and the corresponding training and certification to perform the tasks shall be assured. The Supplier quality system procedures shall be readily accessible to personnel who are responsible for performing works. 7. PRODUCT REALIZATION 7.3 Design and development Special emphasis: The Supplier shall issue a Design Quality Plan identifying the personnel responsible to approve design data. All activities will be controlled by Alenia Design Office as per IAE G 01 Alenia Operative Procedure;



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Design and development activities shall be planned to assure that all the design and technical requirements are taken into account including constrains and performance/environmental conditions. Supplier shall manage the configuration of its hardware and software used in CAE/CAD process, shall demonstrate and shown them on Alenia request 7.4 Purchasing In addition: The Off-Load of design and development activities by Alenia Supplier is allowed, providing that: - The sub-tier has been evaluated and approved by Alenia; - All the Alenia/Airbus Germany technical/quality requirements has been transferred to sub-tier; - The activities will be controlled by Alenia Design Office as per IAE G 01 Alenia Operative Procedure; - The sub-tier suppliers cannot subcontract the design work package or part of it.

The Supplier authorized to purchase raw and standard materials, shall be qualified by Alenia on the basis of a program preventively agreed with Airbus Germany. Through the Quality Assurance Plan approval and after an audit, Alenia will release this qualification. The Supplier authorized to perform special processes, shall be qualified by Alenia on the basis of a program preventively agreed with Airbus Germany. The Alenia Supplier cannot subcontract the work package or part of it without prior agreement and approval by Alenia. Off Load of manufacturing phase by Alenia Supplier is allowed, providing that: the off load that includes special processes, shall be allocated to sub-tier qualified by Airbus Germany or qualified by Alenia and approved by Airbus Germany. List of materials and qualified sources shall be requested to Alenia. Special emphasis: The Alenia Supplier shall maintain active lists of: Material purchased (when authorized), with the following indication:

• Material (raw / standard)



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• Type and specification • Supplier (manufacturer / distributor)

Subcontracted manufacturing phase (off - load), with the following indication :

• P/N(s) • Manufacturing phase • Special processes • Supplier name and address

The above lists will be indicated in the Quality Assurance Plan. Any changes and / or addition to the list, will be submitted to Alenia for approval before implementation. The Alenia Supplier shall periodically validate test reports for raw materials. The Supplier can ask Alenia the possibility for use Alenia supplier authorized for Incoming Inspection Delegation (DCA) or Service Provider. For this purpose the Supplier shall provide to Alenia for approval a procedure issued according to guide lines described in document QFRA/06P.021. 7.5.1 Control of production and service provision In addition: the inspection and testing shall be performed according to documented procedure, this procedure shall specify the resources and methods to be implemented and methods of recording the results. 7.5.2 Validation of processes for production and service provision In addition: Qualification procedure and requirements for the processes subjected to qualification are given in the IAY G05 operative procedure. Process/workshop pair Alenia/Airbus Germany qualification must be obtained before the FAI is closed. 7.6 Control of monitoring and measuring devices In addition:



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The Supplier shall establish and maintain documented procedures to control, calibrate and maintain inspection, measuring and test equipment, including test software, used by the Supplier to demonstrate the conformance of product to the specified requirements. The Inspection, measuring and test equipment shall be used in a manner which ensure that the measurement uncertainty is know and is consistent with the required measurement capability. Special emphasis on: - Accuracy required - Inspection, measuring and test equipment identification - Process employed for the calibration - Records of calibration status - Action taken when inspection, measuring or test equipment is found out of calibration. - Environmental condition of metrological laboratory. - Methods for recall of measuring devices that require calibration. 8.2.2 Internal audit In addition: The Supplier shall conduct internal quality audits that assess compliance to their system and the requirements of this document. Special emphasis on: - Audit planning - Records of audit results - Follow-up audit activities 8.2.4 Monitoring and measurement of product In particular the process “Key Characteristics” for the A380 program shall be identified and controlled using, where possible, statistical techniques (SPC) according to the Quality Assurance Plan approved by Alenia. Special emphasis: According to the nature of the product subcontracted and depending on its criticality and the specified requirements, these techniques may be used to support: - design verification



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- selection and inspection of key characteristics - process capability measurements - statistical process control - Design of Experiments (D.O.E.) - Inspection - Quality Management

When Statistical Process Techniques are applicable the Supplier establish and maintain documented procedure for this activity management. When the Supplier uses sampling inspection as a means of product acceptance, the plan shall be statistically valid and appropriate for use. The plan shall preclude the acceptance of lots whose samples have known nonconformities. The plan shall be submitted for Alenia approval. In addition: Quality Gates: starting from MSN 37, Alenia/Airbus evaluate/monitor the quality of products supplied for each section in accordance with the following indicators:

Title / Status >=MSN 37 >MSN 37+5 >MSN 37 +10 >MSN37 +15

Red >= 75h 60 45 15

Yellow = >22,5h and < 75h

>15h and <60h

>7,5h and <45h

>3,75h and <15h

Outstanding Work HOURS

Green <= 22,5h 15 7,5 3,75

Red >= 3

Yellow = 2 Open concessions Green <= 1

Red No Supplier Final Check Performed Green Yes

Red >= 3

Yellow = 2 Open Modification Green <= 1

Red No On-time Delivery Dossier Green Yes



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8.2.4.1 Inspection documentation Special emphasis: About outstanding work and retrofits the Alenia Supplier must comply with the Alenia quality operative procedure IAY G05. 8.2.4.2 First article inspection (F.A.I.) In addition: A F.A.I. program will be prepared and agreed with Alenia for eventual Alenia / Airbus Germany participation. Special emphasis: The F.A.I. shall be performed in compliance with EN/AS 9102 requirements.