atr special versions foreign programs...

ATR SV FOREIGN PROGRAMS QUALITY REQUIREMENTS FOR ALENIA AERMACCHI SUPPLIERS

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Issue A Rev. / May 2012 Page: 1 of 29

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ATR SPECIAL VERSIONS FOREIGN PROGRAMS

QUALITY REQUIREMENTS FOR

ALENIA AERMACCHI SUPPLIERS

PREPARED BY Supply Chain Quality Assurance / ATR SV Quality Manager G. Giuliano / R. Bosica

APPROVED BY Head of Supply Chain Quality Assurance

R. Andreozzi

CONCURRENCE Head of Quality Military Transp. Programs and Special Versions A/C F. Gaglianello

© 2012 Alenia Aermacchi - Questo documento è di proprietà di Alenia Aermacchi S.p.A. e non può essere riprodotto o il suo contenuto comunicato a terzi senza autorizzazione scritta di Alenia Aermacchi S.p.A. © 2012 Alenia Aermacchi - This document is property of Alenia Aermacchi S.p.A. it shall not be copied or its content shall not be communicated to third parties without written authorisation of Alenia Aermacchi S.p.A.


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Record of Changes

Issue A Rev. /

May 2012

• New Company Name and logo.

• Contents completely revised to extend Para. 2 applicability to A1, B1, D2, E1 and F1 Qualification Classes.

• Applicability limited to ATR Special Versions foreign Programs.

See cover page


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List of Effective Pages

Pag. Issue Rev.

1 - 29 A /

INDEX Page Cover page 1 Record of changes 2 List of effective pages 3 Index 3 1. Scope 5 2. Applicability 5 3. Reference / General 6 3.1 Reference 6 3.1.1 International Standard 6 3.1.2 NATO Military Standards 6 3.1.3 Alenia Aermacchi documentation 6 3.2 General 6 3.2.1 Definitions and Acronyms 7 3.2.1 General principles 8 4. Quality Management System 9 4.1 General Requirements 9 4.2 Documentation management 9 4.2.3 Control of documents 10 4.2.4 Control of quality records 10 4.3 Configuration management 10 5. Management responsibility 11 7. Product realization 11 7.3 Design and development 11 7.4 Purchasing 12 7.5 Production and service provision 14 7.5.1. Control of production and service provision 14 7.5.2 Validation of processes for production and service provision 15 7.5.3 Identification and traceability 17 7.5.4 Customer property 17 7.5.5 Preservation of product 17 7.6. Control of monitoring and measuring devices 18 8. Measurement, analysis and improvement 18 8.2.2. Internal audit 18 8.2.3. Monitoring and measurement of processes 19 8.2.4. Monitoring and measurement of product 19 8.2.5 Evidence of non conformity – Certificate of Conformity 19 8.3. Control of non conforming product 20 8.4 Analysis of data (and exchange data) 21


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8.5 Improvement 22 Attach.1 Alenia Aermacchi sample of Certificate of Conformity (Part I) 23 Attach.1 Alenia Aermacchi sample of Certificate of Conformity (Part II) 24 Attach.2 Alenia Aermacchi sample of Material Review Report – RFW/RFD (Part I) 25 Attach.2 Alenia Aermacchi sample of Material Review Report – RFW/RFD (Part II) 26 Attach.3 Alenia Aermacchi sample of Investigation Report (IR) 28

Note: The above Index is referred to IAY-G-05 paragraphs for which the either additional or emphasized requirements are required.


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1. Scope

This document defines the Quality Management System requirements of Alenia Aermacchi supply chain involved in the ATR42 and ATR72 Special Versions Foreign Programs (e.g.: MP, ASW). Specifically, this document:

• summarizes the Supply Chain QA requirements issued for single commodity (class code);

• emphasizes or adds program requirements with respect to the Alenia Aermacchi Procedure IAY-G-05 “Quality Management System Requirements for Alenia Aermacchi Suppliers”.

Note: In this document, the term “Foreign” has to be intended as “Non Italian”. As

necessary, further requirements relevant for product quality may be also specified and included within Contract and/or Purchase Order technical specifications.

2. Applicability

This document is applicable to Alenia Aermacchi supply chain involved in the ATR Special Versions Program for one or more of the following purchased activities.

Commodity and Product definition Class Code (Ref. IAY-G-05)

Equipments (HW-SW), design and manufacturing of A1

Standard Parts, manufacturer of

Metallic Raw Materials, manufacturer of bars, rods , plates, sheets, extrusions, cut-to-size, castings, forgings.

Non-Metallic Raw Materials, manufacturer of chemicals, paints, adhesives, lubricants, tapes, composite materials.

B1

Build-to-Print (Alenia Aermacchi) Metallic and Non-Metallic,

Recurring supply of Design and Manufacturing activities (including materials’ purchasing)

C1

Recurring supply of Manufacturing activities (including materials’ purchasing) C2

Recurring supply of Manufacturing activities (materials’ purchasing not allowed) C3

Recurring supply of Special Processes tasks only C4

Tooling, design and manufacturing of D1

Aircraft Ground Equipment, Design and Manufacturing of D2

Manufacturer, Stockists and Distributors, for equipments (COTS), standards and raw materials.

E1

Maintenance/Repair/Overhaul of aircraft parts/components F1


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Commodity and Product definition Class Code (Ref. IAY-G-05)

Off-load of Design tasks (with Alenia Aermacchi Design Authority) / Job Cards / Technical Manuals Preparation

H2

3. Reference/General

3.1 Reference

3.1.3 International Standard

a AS/EN 9100 Quality Management Systems – Aerospace Requirements.

b AS/EN 9102 Aerospace First Article Inspection Requirements.

c AS/EN 9120 Quality Management Systems – Aerospace Requirements For Stockists Distributors.

d ISO 9001 Quality Management Systems – Requirements.

e ATA 300 Specification for packaging of airlines supplies.

3.1.3 NATO Military Standards

a AQAP-2110 NATO Quality Assurance Requirements For Design, Development and Production

b AQAP-2210 Supplementary Software Quality Assurance Requirements to AQAP-2110.

c AQAP-2070 NATO Mutual Government Quality Assurance (QA) Process.

d STANAG 4107 Mutual Acceptance Of Government Quality Assurance And Usage Of The Allied Quality Assurance Publications (AQAP).

3.1.3 Alenia Aermacchi documentation

a IAY-G-05 Quality Management System Requirements for Alenia Aermacchi Suppliers

b M123-01 Alenia Tooling Manual

c M123-02 Alenia Tool Design Manual

d Technical supply specification applicable to the work Package/Program

Note: The controlled documentation for Supplier, at last/current revision only, shall be provided by Alenia Aermacchi Procurement personnel.


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3.2 General

3.2.1 Definitions and Acronyms

3.2.1.1 Definitions

Basic Aircraft ATR42 or ATR72-400, -500 or -600 aircraft.

Program ATR Special Versions program and related aircraft operated by End-User.

End-User Foreign Institutional Corps operating an ATR Special Versions aircraft (i.e. Turkish Navy, Nigerian Air Force, etc.).

Customer Alenia Aermacchi.

Supply Chain Alenia Aermacchi Suppliers organization and relevant sub-tiers for ATR42 and ATR72 SV programs.

Supplier All sellers supplying parts/services included within the recognized Alenia Aermacchi Supply Chain.

3.2.1.2 Acronyms

AIR Assembly / Aircraft Inspection Report

ASW Anti Submarine Warfare

ATP Acceptance Test Procedure

CDR Critical Design Review

CM Configuration Management

CMP Configuration Management Plan

COC Certificate of Conformity

COTS Commercial Off The Shelf (equipments)

DDP Declaration of Design and Performance

DR Defect Report

ENAC Ente Nazionale Aviazione Civile

EASA European Aviation Safety Agency

FAA (US) Federal Aviation Administration

FACI First Article Configuration Inspection

FAI First Article Inspection

FO Foreign Object

FOD Foreign Object Debris/Damage

HW Hardware

IR Investigation Report

MP Maritime Patrol

MRB Material Review Board

MRR Material Review Report

NATO North Atlantic Treaty Organization

NDI Non Destructive Inspection


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NDT Non Destructive Test

PCD Process Control Document

PDR Preliminary Design Review

PN Part Number

PO Purchase Order

QA Quality Assurance

QAP Quality Assurance Plan

QMS Quality Management System

RFD Request For Deviation

RFW Request For Waiver

SAP System Analysis and Program development software

SB Service Bulletin

SDRL Supplier Data Requirement List

SN Serial Number

STTE Special To-type Test Equipment

SV ATR 42-72 Special Versions (e.g.: MP, ASW types)

SW Software

TSO Technical Standard Order

3.2.2 General principles

3.2.2.1 General Special emphasis: Supplier shall ensure its QMS is defined according to AS/EN 9100 International and/or equivalent AQAP Military Standards, and is third party registered by an International or a Military Aerospace Quality Group approved no later than the Contract/PO execution. Moreover, the Supplier shall undergo to Alenia Aermacchi qualification and to be included in the "List of Alenia Aermacchi Qualified Suppliers”. Supplier shall be also able to meet Contract/PO requirements, including Quality Requirements before starting production activities. In case of non compliance with Contract/PO requirements, the Supplier shall put in place all the necessary initiatives required by Alenia Aermacchi to demonstrate its QMS improvement (e.g. Quality Improvement Plan).

Surveillance and right of access In addition: ATR SV foreign program activities performed by Suppliers are subjected to a Customer/Institutional evaluation by advance capability assessment and/or by on-site surveillances during production, as necessary. For the purpose, Supplier shall provide or obtain for

• Alenia Aermacchi representative,

• End-User/Institutional Representative (see also paragraph 9 of AQAP-2110);


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• regulatory agency personnel (as required)

right of access to any facilities where work is being performed or is scheduled to be performed, including those facilities of Supplier’s subcontractors, in order to perform system/process surveillance or item inspections, as a part of conformance verification to the requirements of the Contract/PO.

4. Quality Management System 4.1 General Requirement In addition: The Supplier shall prepare a Quality Assurance Plan (QAP) in accordance with Alenia Aermacchi form IAY-G-05 Attachment 1, to define and demonstrate its compliance to ATR SV quality requirements referred to the documents at “3.1 Reference” paragraph. The above QAP must be submitted to the Alenia Aermacchi Quality Assurance for approval. 4.2 Documentation Management Special emphasis: Supplier’s QMS procedures shall be readily accessible to the personnel who are responsible for performing works. Changes in QMS and QMS procedures shall be notified to Alenia Aermacchi in writing for evaluation and possible impacts on ATR SV foreign Programs. In addition: The Supplier shall comply Alenia Aermacchi requirements and define written instructions supporting ATR SV quality initiatives that shall be reported within QAP in order to state, but not limited to, the following:

• HW and SW design review (as applicable); • Configuration and change management; • Parts inspection and certification; • Equipments qualification (ATP, DDP); • FAI and FACI management (as applicable); • Parts and Equipments non conformity management; • Preventive and Corrective Actions implementation; • FOD prevention plan.

In case of SW specifically developed for ATR SV foreign programs, SW requirements shall be detailed within QAP according to AQAP-2210 “Supplementary Software Quality Assurance Requirements to AQAP-2110”. The activities will regard the entire SW life cycle consisting, as a minimum, with:

• Development phase definition; • Check and validation of SW products;


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• Check of instruments and test-set used for SW validation; • Documents delivered with SW products.

Supplier QAP shall be submitted to Alenia Aermacchi for review and approval no later than thirty (30) days after PO effective date. All sorts of amendments and changes to initial QAP shall be submitted to Alenia Aermacchi for approval prior to implementation.

Subcontractors Quality Plans and all documentation regarding ATR SV quality as well as system, processes and products reported in QAP shall be made available to Alenia Aermacchi upon request. 4.2.3 Control of documents

In addition: Digital data management - When Alenia Aermacchi provides digital data and/or access to an interactive Alenia Aermacchi data library for design, production and inspection initiatives, the Supplier shall establish an internal data management system to be described even in the QAP if required. Documents and data can be in the form of any type of media, such as hard copy or electronic media.

Documents changes - Supplier shall establish a process to ensure the timely review, distribution, implementation and maintenance of documents (i.e. drawings, standards, specifications, planning and changes) both issued internally and received from Alenia Aermacchi. Record of changes for all QMS and ATR SV documentation shall be also maintained. Technical specification changes - Within 30 days from the transmission of any revised technical specification, the Supplier shall provide Alenia Aermacchi the evidence of the change evaluation and the identification of possible impacts on ATR SV activities. 4.2.4 Control of quality records

In addition: The supplier shall control and maintain quality records according to Alenia Aermacchi requirements. All quality records shall be made available for review by Alenia Aermacchi, End-Users/Institutional or Regulatory Authority at least for ten (10) years. 4.3 Configuration Management In addition: The Supplier shall establish a ATR SV Configuration Management (CM) policy based on the following standards:

• EN/AS 9100 (International Standard) • AQAP-2110 (NATO Standard)


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Based on the reference above, the Supplier shall prepare a Configuration Management Plan (CMP) which describes the application of CM to the ATR SV Foreign Programs. The CMP content, that may be part of QAP, if appropriate, will describe as a minimum:

• Configuration Identification • Configuration Control • Configuration Status Accounting • Configuration Audit (physical and functional).

Changes impacting the configuration items and documentation (i.e. drawings, catalogues, technical manuals, etc.) defined per PO, shall be managed in accordance with the configuration management rules adopted for ATR SV foreign programs. Moreover, all changes required by the Supplier and affecting fit, form and function of the deliverable item shall be subjected to approval before their implementation. All changes needed after aircraft delivery shall be subjected to SB processes and authorization managed by Alenia Aermacchi – Customer before items modification. Additional modifications required by A/C Manufacturer (i.e. ATR) or by institutional bodies (e.g. EASA, DGAC, ENAC, etc.), thru Service Bulletins or Airworthiness Directives respectively, shall be also subjected to Alenia Aermacchi and/or Institutional Body approval before implementation.

5. Management Responsibility In addition: Supplier’s organization or personnel dedicated to ATR SV foreign Programs shall be defined and reported within QAP. A quality manager or a focal point for ATR SV quality shall be indicated and shall have authority for solving any quality problem. When changes regarding facility location, management representative or any other major aspects of QMS occur, the Supplier shall immediately inform Alenia Aermacchi in writing,

7. Product Realization

7.3 Design and development

In addition: As applicable for the work package assigned to the Supplier, the design and development activities for parts and equipments shall be detailed within the Supplier’s QAP. A responsible for Design and Development, so as the personnel having the responsibility to approve the technical documentation (i.e drawings, technical specification, etc.) shall be also defined.


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In order to support product realization, the Design and Development phases as well as design planning, verification, validation and changes shall be considered and managed, as a minimum, thru the following initiatives:

• Design input/output definition; • Preliminary Design Review (PDR); • Critical Design Review (CDR); • Product Qualification (i.e. FACI, DDP, FAI); • Product Life Cycle Review.

Systems and equipments qualification process Systems and equipment qualification process (technical specification, qualification test plan and procedures, acceptance test procedures, test reports and Declaration of Design and Performance) shall be carried out in compliance with Alenia Aermacchi technical specification and certification requirements. Special emphasis about reliability, maintainability, availability and safety analysis shall be also considered. The Technical Standard Order (TSO), the physical and functional configuration audits (FACI process) and the final Declaration of Design and Performance (DDP), will demonstrate the systems and the equipment certification/qualification status.

7.4 Purchasing In addition: The Supplier ensure that Alenia Aermacchi quality requirements are fully understood and accurately applied to PO deliverable items and flowed down to the affected organizations and/or sub-tier suppliers involved in the ATR SV Foreign Programs. The Supplier cannot subcontract the work package or part of it without a prior make-or-buy process evaluation and QAP approval stated by Alenia Aermacchi. Moreover, all Special Processes performed and/or subcontracted by sellers and included in the type list reported below shall be allocated to the Alenia Aermacchi recognized sub-tiers only.

Special Process Type List (as applicable) • Bonding • Brazing • Casting • Chemical Milling • Composites Fabrication • Fasteners Installation (Composite only) • Forging and Forming • Hardness and Conductivity • Heat treatments • Paint and Prime


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• Non-Destructive Testing • Sealing (training only) • Shot Peening • Surface Chemical Treatments • Welding.

List of Supplier’s sub-tiers As applicable for PO contents, the Supplier shall maintain and reported (as applicable) within the QAP an active list of its sub-tiers which includes the following provisions:

• Equipments (HW and SW).

• Raw Materials and Standard;

• Manufacturing off-load

• Special Processes;

• Tooling;

As a minimum, the Supplier shall collect and list the following sub-tier information:

• Manufacturer/Distributor Identification;

• QMS third party recognitions and status;

• Part number-types or processes description;

• Technical specifications reference;

• Quality requirements reference. As applicable for PO content, the above lists shall be included or addressed in the Supplier QAP, to be submitted to Alenia Aermacchi Quality Assurance for approval before Supplier implementation. Purchasing of raw materials and standards Raw materials and standards required by Alenia Aermacchi engineering drawings shall be purchased according to the relevant technical and quality specifications therein specified. Materials sources needed for the purpose (either manufacturer or distributors) shall be also qualified suppliers approved by Alenia Aermacchi thru the Supplier QAP. Raw material, chemical/perishable material and standards purchased by the Supplier for ATR SV Program shall be received with the Certificate of Conformity and Test Report issued by the Manufacturer. The method used to perform the incoming inspection and the frequency of inspection shall be described in an Internal Procedure or in the QAP (as required), and submitted to Alenia Aermacchi for approval. In accordance with IAY-G-05 “Monitoring and measurement of product” rules, the use of Manufacturers or Distributors already approved by Alenia Aermacchi for “Incoming Inspection


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Delegation and Reduced Purchaser Testing”, even if considered, shall be subjected to Alenia Aermacchi authorization. Purchasing of Commercial Off The Shelf (equipments) In addition to the Certificate of Conformity (CoC), equipments defined as COTS shall be purchased and/or provided to Alenia Aermacchi with the manufacturer source data as well as Technical Standard Order (TSO) and Declaration of Design and Performance (DDP).

Note: A Technical Standard Order (TSO) is a minimum performance standard issued by the FAA or EASA for specified materials, parts, processes, and appliances used on civil aircraft. Articles with TSO design approval are eligible for use on the United States or Europe type certificated products. The TSO authorization or a letter of TSO Design Approval does not necessarily convey approval for installation.

7.5 Production and service provision 7.5.1 Control of production and service provision

In addition Alenia Aermacchi and Institutional authorities reserve the right to perform surveillance and source inspection of processes and products directly at Supplier plants. For the purpose, these activities will be focused on the following:

• Surveillance, to verify that QMS and PO Quality Requirements are properly applied and controlled by Supplier’s Quality department;

• Source Inspection, to concur with the Supplier’s Quality department to the first (FACI-FAI) and recurring article inspections and relevant part acceptances before delivery.

7.5.1.1 First Article Configuration Inspection and First Article Inspection

FACI

In addition: First Article Configuration Inspection (FACI) is required for equipment qualification, prior to delivery of the equipment first production unit. The Supplier shall prepare a FACI schedule and notify Alenia Aermacchi ten (10) working days in advance of the date when the item is ready for FACI. This inspection will be accomplished with both Supplier and Customer/End User (when confirmed) participation on a development equipment for first acceptance/qualification. This inspection covers the item or assembly, including its component parts and associated software, drawings, job cards or any other data related to its conformance to PO


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requirements. In detail, FACI activity will be performed to verify, as a minimum, the following tasks:

• Identification of the unit subjected to FACI; • Cross check between assy/component drawings and HW-SW as-built configuration; • Dimensional verification of critical characteristic (coupling/interface measures); • Manufacturing Process; • Waiver/Deviation check of the unit subjected to FACI (if any); • Bough-Out components check; • Assembly Policy (job cards and FOD prevention policy); • Identification and marking (labelling); • Certificate of Conformity of the supply components; • Test Procedure accepted by Alenia Aermacchi; • Qualification Test Procedure accepted by Alenia Aermacchi; • Preliminary Test Report; • Configuration Documentation for STTE (Special To-type Test Equipment).

FAI Special emphasis: The purpose of EN/AS 9102 First Article Inspection is to provide objective evidence that all engineering, design and specification requirements are correctly understood, accounted for, verified, and recorded by the Supplier. All part features shall be accounted for and documented on the EN/AS 9102 forms and retained by the Supplier. After completion of the non recurring activity related to FAI process, all parts and assemblies shall be subjected to the recurring inspections. In addition: In addition to EN/AS 9102 requirements, the Supplier shall prepare a FAI schedule and notify Alenia Aermacchi ten (10) working days in advance of the date when the product is ready for FAI, for Customer/End User (when confirmed) participation to the on-site FAI initiatives. 7.5.2 Validation of processes for production and service provision

In addition: Suppliers and relevant sub-tiers shall meet the Quality Requirements reported on the latest version of this document and will validate processes, products and services by ATR SV documents that will be provider to Alenia Aermacchi in accordance with the following Supplier Data Requirement List (SDRL):


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Table 1 - Supplier Data Requirement List (SDRL)

Deliverable Data Quality Requirement

Reference Supplier Class

Non-Recurring Recurring

General IAY-G-05

(4.2.1)

A1; C1; C2;

C3; D1 QAP issue

QAP updating (as necessary)

A1 Manufacturer

Qualif (TSO, DDP) --- Design and

development validation

IAY-G-05

(7.3.6) E1 Source Qualification

(TSO, DDP) ---

A1; B1; C1; C2;

C3; C4; D2; E1, F1 ---

Inspection or Functional Test Report (ATP) Control of

production and service provision

IAY-G-05

(7.5.1)

H2 ---

Structural Calculation/Analysis

Report (if applicable)

First Article Inspection (FAI)

IAY-G-05

(7.5.1.1) A1; B1; C1; C2; C3 FAI Report ---

First Article Config. Inspection (FACI)

IAY-G-05

(7.5.1.1) A1 FACI Report ---

C4 Processes

Certification Report ---

IAY-G-05

(7.5.2) D1

Tooling Inspection Report

---

IAY-G-05

(7.5.2), (8.2.4.3)

A1; B1; C1; C2;

C3; C4; E1; F1; H2 ---

Certificate of Conformity

Validation of processes for production and service provision

IAY-G-05

(7.5.2), (8.2.4.3) D1; D2

Certificate of Conformity

---

Identification and traceability

IAY-G-05

(7.5.3)

A1; E1

(for equipment only) LOG Card (when required)

---

Control of non-conforming product

IAY-G-05

(8.3)

AER(EP).Q-2101

(additional to 8.3)

A1; B1; C1; C2; C3; C4; D1; D2; E1; F1

--- Non Conforming Product Report

Control of non-conforming product (for equipment after deliver only)

IAY-G-05

(additional to 8.3) A1; E1; F1 --- Investigation Report

Note: All IAY-G-05 supplier classes are reported. Verify the applicable items per PO and apply deliverable requirements of Table 1 as appropriate.


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7.5.3 Identification and traceability

In addition: All products, physically identified per engineering drawings, shall include stamps, nameplates or labels reporting, as appropriate:

• Name of the Organization;

• Part Number (PN);

• Serial Number (SN);

• SW release number;

• Lot Number and Organization Work Order Number;

• Acceptance Date (for test bench);

• Production Date (for expiring items);

• Assembly Date (for assemblies with expiring items).

7.5.4 Customer property

In addition: The Supplier shall inventory Customer/End User products in order to avoid that these products could be sold or provided to any third party without any written Alenia Aermacchi authorization. 7.5.4.1 Non disclosure agreement about technical data If Customer/End User technical data are provided, the Supplier shall agree that it: • will limit the use of technical data to the manufacture of the item specified on the PO; • will not disclose data to any other subjects except Alenia Aermacchi qualified suppliers and their subcontractors as involved in ATR SV Foreign Programs;

• will not attempt or allow any person to acquire any right in technical data; • will flow down the same restrictions within sub-tiers PO. Upon direction by Alenia Aermacchi, Supplier agrees to destroy or return all of the technical data exported pursuant to the PO upon completion of the same PO. 7.5.5 Preservation of product The Supplier shall ensure the compliance with preservation and packaging requirements defined in the ATA300 specification. When the requirements are not requested per PO contents, the Supplier shall ensure the use of adequate packaging methods and of any other protective means to prevent the product from damaging and deterioration.


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7.5.5.1 Verification of product before delivery Before delivery, the Supplier shall verify that all parts are: • properly identified; • completed as per PO requirements; • free of damages and FO; • adequately packaging; • inclusive of the delivery documents (SDRL). 7.5.5.2 FOD Prevention Plan In addition: When assemblies of parts and/or equipment are applicable per PO activities, Suppliers and relevant sub-tiers shall prepare a FOD Prevention Plan adopting all the necessary initiative (i.e. working areas control, practices definition, personnel training, etc.) to prevent FO entrapment, migration and FO damages. Supplier decision to include FOD prevention instructions within the QAP document only may be also adopted.

7.6 Control of monitoring and measuring devices

In addition: The Supplier shall establish and maintain documented procedures to control, calibrate and maintain inspection, measuring and test equipment, including test software, to be 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 that the measurement uncertainty is known and it is consistent with the required measurement capability.

8. Measurement, Analysis and Improvement 8.2.2 Internal audit In addition: The Supplier and its sub-tiers shall conduct annual audits to demonstrate compliance both to QMS and ATR SV quality requirements reported in this document.


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8.2.3 Monitoring and measurement of processes

Special emphasis: The Supplier shall define methods for controlling QMS processes used in the ATR SV programs. These methods can include PCDs, to demonstrate the ability of the processes to achieve the expected results. In the event of process nonconformity, the Supplier shall take appropriate actions to correct the nonconforming process. In order to evaluate any possible impact in the process-product discrepancy, process control shall be applied and maintained throughout the product life cycle. 8.2.4 Monitoring and measurement of product In addition: Products, processes, services verification and acceptance criteria shall be performed and documented in accordance with the requirements reported in Table 1 - Supplier Data Requirement List.

8.2.4.1 Inspection documentation

In addition: The inspection activities shall be managed in accordance with the documented reporting initiatives divided into the following phases: 1. Non Recurring (FACI and FAI, see also para 7.5.1.1):

• All part feature data captured for each item (HW and SW) • Baseline for configuration and all process measures and inspections.

2. Recurring:

• Only major data collected for each part • Control Plan (i.e. AIR, PCD, etc.) implemented and proven.

8.2.5 Evidence of non conformity – Certificate of Conformity

In addition: Supplier shall prepare a Certificate of Conformity (COC) asserting that the Items contained within the shipment are in total compliance with the technical and quality requirements of Contract/PO. For the purpose, Supplier shall use:

• the form in Attachment 1 (Ref. AQAP-2070, Annex B) or

• its own form, provided that all requested information are listed.


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The Supplier shall annotate all non conformities (Major and Minor) in the COC document. Copy of COC form and the existing MRR forms, shall be included in the delivery package and verified by Alenia Aermacchi during the incoming inspection for compliance.

8.3 Control of non conforming product

In addition Types of discrepancies in quality and technical requirements revealed during manufacturing phases are grouped in three different classes of RFW-RFD and summarized as follows:

• MAJOR: Non Conformity affecting the design requirements and that, after the introduction of the corrective action, limits the technical/operative functions of the final product

• MINOR: Non Conformity affecting the Design requirements and that, after the introduction of the corrective action, does not limit the technical/operative functions of the final product. Non conformities impacting the appearance of products inspected by Scheduled Inspection Manual are also classified as MINOR;

• MINOR NON RECORDABLE: Non Conformity that, after the introduction of corrective action, does not affect the requirements related to MAJOR and MINOR classes anymore.

All products affected by

• either Major or Minor Non Conformities shall be subjected to both Alenia Aermacchi and Customer acceptance, through MRB, before use

• Non Recordable Non conformities shall be subjected only to Alenia Aermacchi acceptance before use.

When a discrepancy occurs, the Suppliers is responsible to perform the following activities:

• record and provide to Alenia Aermacchi the non conformity data through RFW-RFD form;

• identify and segregate the non conforming product;

• propose the RFW-RFD technical disposition for all RFW-RFD classes;

• process the MINOR NON RECORDABLE RFW-RFD (for Supplier with technical authority only);

• carry out and certify the operations related to RFW-RFD technical disposition;

• report MAJOR and MINOR RFW/RFD in the COC form;

• include MAJOR and MINOR RFW/RFD in the shipping documentation;

• file all RFW-RFD documentation and make it available to Alenia Aermacchi on request;

• perform RFW-RFD analyses and maintain RFW-RFD quality metrics.


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All RFW-RFD shall be managed electronically, either by SAP, an automatic data processing SW used by Alenia Aermacchi, or by the relevant form reported in Attachment 2 (Part I & II).

Defective equipments

Faulty equipments furnished by Supplier and its sub-tiers shall be managed through the defect-investigation (DR-IR) process. When a DR is issued by Alenia Aermacchi for defective equipments (see Table 2), Supplier shall evaluate DR data, conduct a detailed investigation and inform Alenia Aermacchi in writing about causes of defect and relevant remedies by filling the IR form reported in Attachment 3 (Part I). Equivalent internal IR form including the minimum information listed in Attachment 3 (Part II) may be also used.

Table 2 - DR-IR Flow Chart

8.4 Analysis of data (and exchange data)

In addition: Management of data regarding measurement, analysis, certification and improvement of materials are supported by forms and exchange data methodologies described, both in the this document and in those listed in 3. Reference/General paragraph. The use and distribution of Alenia Aermacchi forms and data shall be subjected to Alenia Aermacchi authorization and managed in accordance with Alenia Aermacchi requirements.


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8.5 Improvement

8.5.1 Continuous improvement

In addition: In order to assure product quality enhancement, the Supplier shall continually improve the effectiveness of its QMS through the use of methodologies of review, surveillance and data analysis including, but not limited to, the following:

• planned reviews

• schedules control;

• data collection;

• quality metrics;

• cause/effect diagrams;

• corrective/preventive actions;

• audits result/scoring.


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Attachment 1 - Alenia Aermacchi Sample of Certificate Of Conformity Form (Part I)


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Attachment 1 - Alenia Aermacchi Sample of Certificate Of Conformity Form (Part II).


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Attachment 2 - Alenia Aermacchi sample of Material Review Report – RFW/RFD (Part I)

Note: the minimum info required are referred to the blue fields marked above.


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Attachment 2 - Alenia Aermacchi sample of Material Review Report – RFW/RFD (Part II)


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Attachment 2 - Alenia Aermacchi instruction guide for RFW/RFD completion

Id. Field Description

1 N° RFW/RFD Identification number

2 Concession / Application Number of internal /supplier non-conformance report

6 Drawing /PN Drawing or Part Number identification

7 Part Name Part or equipment affected by the non-conformance

10 Serial Number Serial Number (SN), if applicable

11 NC Aircraft SN or production id, if applicable

15 Defect Code Defect Code, if required

16 Defect Cause Code Defect Cause Code, if required

17 Re-Order Code Material Restore Code, if required

19 EDRR Request of egineering drawing change related to the non-conformance technical disposition

30 Purchese Order Reference of Alenia Aermacchi Purchase Order (PO)

31 Supplier Supplier company name

34 Held quantity Number of parts impacted by the non-conformance

39 Simm. “Yes” or “Not” marking, whether a symmetrical part is further involved

40 Defect description Description and data relevant to the non-conformitance detected

41 QC Instector Name and signature of supplier Quality Control Inspector leading the non-conformance

42 Description defect cause Root cause analisys and description of the non-conformance

43 Action to remove the cause Description of the corrective action eliminating the root cause of the non-conformance

44 Manufacturing/repair resp. Name and signature (after repair) of the Supplier Manufacturing resp.

54 Note Notes regarding additional info, sketchs or attached drawings


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Attachment 3 - Alenia Aermacchi sample of Investigation Report (IR)

INVESTIGATION REPORT

DEFECT REPORT N° ISSUE SHEET

0 1 2 3 4

SPECIFICATION/DRAWING N° 5

WARRANTY 6

DATE 7

SUPPLIER CODE DESCRIPTION

8

9 10

PART NUMBER MOD STD SERIAL NUMBER

11

12 13

INVESTIGATION REPORT

14

ACTION TAKEN TO RECTIFY EQUIPMENT

15

CAUSE OF DEFECT

16

DESIGN FAULT

�

MANUFACT. FAULT

�

MATERIAL DEFECTIVE

�

MISHANDLING

�

INCORRECT MAINTEN.

�

EXTERNAL CAUSE

� INFANT MORTALITY

�

F.O.D.

� MISOPERATION

�

SOFTWARE ERROR

� INSTALLATION PROBLEM

�

UNKNOWN

� QUALITY PROBLEM

�

NOT FAULT FOUND

� COMPONENT DEFECT

�

OTHERS

�

ACTION TO PREVENT RECURRENCE

17

TECHNICAL LIABILITY ACCEPTED : 18

YES � NOT �

DISTRIBUTION

MANUFACTURER SIGNATURE SUPPLIER SIGNATURE 19

20

21

Q.A DATE Q.A DATE

N.Q.A.R. DATE N.Q.A.R. DATE DATE CLOSED BY Q.A.

22


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Attachment 3 - Instruction guide for Investigation Report (IR) completion

(IR minimum info required)

Id. Field Description

0 Logo Logo of the company

1 Program name Name of the program (e.g. P72A, ASW, etc)

2 Defect Report N. It is the DR N. on which the IR is based

3 Issue The issue of the IR.

4 Sheet The N° of the pages compose the IR (I.E. 1/1; 1/2 …)

5 Specification/Drawing N° The drawing of the part number

6 Warranty “YES” if the item is covered by warranty, “NOT” if the item is not covered by warranty.

7 Date Issue date of the IR.

8 Supplier Name of the Supplier

9 NATO Code NATO Code of the Supplier

10 Description Name of the item

11 Part Number Part Number of the defective item

12 Mod STD MOD Status if applicable

13 Serial Number It is the Serial Number of the item

14 Investigation Report Result of the investigation.

15 Action taken to rectify equipment

Describe the action taken to rectify equipment. Describe possible action to prevent the recurrence of the defect on item already delivered.

16 Cause of defect Cause that caused the defect.

17 Action to prevent recurrence Describe the action to prevent the recurrence of the defect.

18 Technical Liability Accepted “Y” if the Supplier accepts the Liability, “N” if the Supplier does not accept the Liability.

19 Distribution Name and company to whom the IR is sent.

20 Manufacturer signature

(when Applicable)

Signature and date of Manufacturer Quality.

21 Supplier signature Signature and date of Supplier Quality.

22 Date closed by Alenia Q.A. Authorization signature and authorization date of Alenia Aermacchi Quality.