hundreds of cmc customers’ questionnaires. … · the marconi wireless telegraph company of...
TRANSCRIPT
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Dear Customer, Esterline CMC Electronics continuously receives requests from customers to fill out quality surveys and other documents. As you can appreciate each of these individually unique formats can require significant time and effort to complete. In order to facilitate the process and respond to you much quicker we have incorporated and consolidated the questions into a Standard Survey Response package that we will provide to all requests in the future. This document, as a complement to the quality manual, gives general and specific information about CMC Electronics (Canadian and Sugar Grove (Ill.) operations). It is a compilation of the results of hundreds of CMC customers’ questionnaires. We trust that this will satisfy your request and look forward to continued excellent relations. If I can be of further assistance I may be contacted at your convenience. Sincerely, I hereby certify that the information in this survey is valid and current.
Olivier de Brouwer, P. Eng. Director, Quality Assurance 514-748-3000 X4127 514-748-3139 [email protected]
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KEY MANAGEMENT CONTACTS
Michel Potvin President, Avionics Systems Tel. : (514) 748-3000 Fax : (514) 748-3025 [email protected]
Robin St-Arnaud President, CMC Electronics Tel. : (514) 748-3000 Fax. : (514) 748-3025 [email protected]
Kristof Vierin Vice President, Sales Tel: +32 56 27 2350 Fax: +32 56 233 588 [email protected] Richard St-Germain Director, Operations Tel: (514) 748-3000 Fax: (514) 748-3061 [email protected]
Patrick Champagne Vice President, Products, Display Solutions Tel: (514) 748-4100 Fax: (514) 748- 3061 [email protected] Don Paolucci Vice President, Navigation & Integrated systems Tel. : (514) 748-3000 Fax. : (514) 748-3061 don.paolucci@ cmcelectronics.ca
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Claude Chidiac Vice President, Products, Strategy & Customer Support Tel.: (514) 748-3000 Fax.: (514) 748-3061 [email protected] Jim Brennan Director, Customer Support Tel: (514) 748-3000 Fax: (514) 748- 3139 [email protected] Olivier de Brouwer, Director, Quality Assurance and Continuous Improvement Tel: (514) 748-3000 Fax: (514) 748-3139 [email protected]
Salim Ramji Director, Airworthiness & Quality Engineering Tel: (514) 748-3000 Fax: (514) 748-3139 [email protected]
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TABLE OF CONTENTS
KEY MANAGEMENT CONTACTS .............................................................................................................. 2
1. INTRODUCTION ................................................................................................................................... 6
2. CMC ELECTRONICS HISTORY ........................................................................................................... 7
3. ACRONYMS .......................................................................................................................................... 8
4. CMC PRODUCTS / SERVICES PRESENTATION AND MAIN CUSTOMERS .................................... 8 4.1 Aviation Products ............................................................................................................................... 9 4.2 Cockpits & Systems Integration ......................................................................................................... 9 4.3 Custom Electronics ............................................................................................................................ 9 4.4 Repair and Overhaul Program ......................................................................................................... 10
4.4.1 Return Procedures Material Authorization (RMA) ................................................................. 10 4.4.2 Warranty ................................................................................................................................ 11 4.4.3 "Out-of-Warranty" Equipment Repairs and Related Rentals ................................................ 11 4.4.4 Firm Fixed Repair Prices ....................................................................................................... 11 4.4.5 Web site link: ......................................................................................................................... 11
4.5 Subcontracting ................................................................................................................................. 11
5. MAIN SUPPLIERS LIST...................................................................................................................... 12
6. FINANCIAL DATA ............................................................................................................................... 12
7. CMC QUALITY SYSTEM .................................................................................................................... 12 7.1 New product or product modification ................................................................................................ 12 7.2 Quality Control .................................................................................................................................. 12 7.3 List of pertinent approvals certificates (See copies in appendix ) .................................................... 13
8. CONTINUOUS IMPROVEMENT ......................................................................................................... 14 8.1 Balanced Scorecard ................................................................................. Erreur ! Signet non défini. 8.2 Lean/Six-Sigma ................................................................................................................................ 14
9. HOUSING, FACILITIES AND SECURITY .......................................................................................... 14
10. OPERATION AND TEST CAPACITY ............................................................................................. 15
11. CERTIFICATES - ............................................................................................................................. 16 11.1 The Canada Border Services Agency .......................................................................................... 16 11.2 ISO 14001 Environmental Management System ......................................................................... 16 11.3 Certificate of approval AMO (maintenance) - Transport Canada ................................................. 16 11.4 Certificate of approval Manufacture - Transport Canada ............................................................. 16 11.5 ISO 9001 and AS9100 .................................................................................................................. 16 11.6 Certificate of Canadian control Goods program ........................................................................... 16 11.7 EASA ............................................................................................................................................ 16 11.8 NADCAP for electronics ............................................................................................................... 16 11.9 Processing Navigation data – FAA – Transport Canada.............................................................. 16 11.10 Capabilities list .............................................................................................................................. 16 11.11 MIL-PRF-38534 hybrid microcircuit certification (custom electronics) ........................................ 16 11.12 Russian FAVT certificate FP145 .................................................................................................. 16 11.13 Certificate CAAC (China) .............................................................................................................. 16 11.14 Hong Kong Civil Aviation Dept ..................................................................................................... 16 11.15 Certificate of appreciation DND A300 program ............................................................................ 16
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1. INTRODUCTION
Esterline CMC Electronics general info
CMC Electronics (www.esterline.com/avionicssystems) designs and produces leading technology electronics products for the aviation and global positioning markets. CMC’s focus is on delivering innovative cockpit systems integration and avionics solutions to its customers worldwide. Its principal locations are in Montreal, Quebec; Ottawa, Ontario; and Chicago, Illinois.
CMC Electronics is a wholly-owned subsidiary of Esterline Corporation (NYSE:ESL, www.esterline.com), a specialized aerospace and defense company headquartered in Bellevue, Washington. Its key markets are commercial aviation (40%), military aviation (40%) and industrial applications (20%). Its three principal business areas are Avionics and Controls; Sensors and Systems; and Advanced Materials. Esterline is 2 billion dollars company with over 13,000 employees around the world.
Name of Organization CMC Electronics Inc.
Montreal
Sugar Grove Ottawa
Address
600 Dr. Frederik Philips Boulevard Ville St-Laurent, Quebec Canada, H4M 2S9
84 N Dugan Rd P.O. Box 250 Sugar Grove, IL 60554 United States
415 Legget Drive, Suite 100 P.O. Box 13330 Kanata, Ontario Canada K2K 2B2
Phone 514-748-3000 630-466-4343
613-592-6500
Fax 514-748-3136
630-466-4358 613-592-7427
email [email protected]
Web site www.esterline.com/avionicssystems
Plant
Total surface sq. ft (sq. m) 268,000 (24 900) 45,000 (4 182) 83,259 (7,736)
Factory sq. ft (sq. m) 155,000 (14 400) 11,000 (1 022) 19,979 (1 855)
Offices sq. ft (sq. m) 113,000 (10 500) 12,000 (1 115) 63,280 (5,880)
Staff
Number of employees 781 56 73
Administration 216 28 32
Engineering 175 17 35
Production 115 9 0
Inspectors 35 0
QA/QC
Director & Mgrs 59 1 2
Engineers 12 3
Technicians 9 1
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2. CMC ELECTRONICS HISTORY
The Marconi Wireless Telegraph Company of Canada was founded in 1903. The name of the company was changed to Canadian Marconi Company in 1925. For the past century, the company has consistently provided its customers with innovative and highly reliable products and its employees with challenging and rewarding career opportunities. Below are some of the historic highlights that have contributed to CMC Electronics’ reputation as an industry leader in aerospace and communications.
Year Event
1901 World's first trans-oceanic wireless transmission.
1903 Marconi's Wireless Telegraph Company of Canada incorporated.
1921 First home radio receivers in Canada.
1925 Company name changed to Canadian Marconi Company.
1931 Establishment of the Canadian radio network, which became the CBC.
1951 TV receivers designed and manufactured.
Trans Atlantic Telecommunications services later known as Teleglobe Canada, acquired by Canadian Government.
1953 English Electric Company Limited of the U.K. acquired 50.6% of Canadian Marconi.
1956 First Canadian company to design a complete microwave radio relay system, the Mid-Canada Defense Line.
1957 First to develop an FM-CW Doppler radar for air navigation.
1960s Focus on aircraft navigation, monitoring and display systems and radar.
1972 Broadcasting operation sold.
1970s to present
High-end aviation and positioning markets
Commercial and defense markets
Equipment supplier and systems integrator
2000 Company name changed to BAE SYSTEMS CANADA INC.
2001 Company name changed to CMC Electronics Inc.
2002 Acquired Flight Visions Inc. in Sugar Grove Ill.
2007 Company acquired by Esterline.
2010 Acquired intellectual property of SmartDeck cockpit
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3. ACRONYMS
AMO Approved Maintenance Organization CMM Capability Maturity Model CMC CMC Electronics Inc. DOD Department of Defense FAI First Article Inspection ISO International Standard Organization MBR Management Business Review NCSLI National Conference Of Standards Laboratories RMA Return Material Authorization SB Service Bulletin SEI Software Engineering Institute SECU Spoiler Electronic Control Unit SIB Service Information Letter SPC Statistical Process Control
4. CMC PRODUCTS / SERVICES PRESENTATION AND MAIN CUSTOMERS
Esterline CMC Electronics is a world leader in the design, manufacture, sales, repair, overhaul and support of high-technology electronics products for the aviation and global positioning markets. The company is a major supplier to the aerospace and high technology industries, airlines, military agencies and government customers around the world.
The sales distribution by domain is:
Domain % of sales
Military / Civil 50 / 50
Government / Commercial 40 / 60
NOTES: * CMC’s DOD cage code is 90073 for Canadian operations and 023M5 in Sugar Grove.
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The following tables present the main Products / Services and key customers:
4.1 Aviation Products
4.2 Cockpits & Systems Integration
Cockpit systems integration
Cockpit Avionics Upgrades
Mission computing and processing systems
Display and control systems
Head Up Displays (HUDs)
Navigation sensors
Human factors engineering
Integrated Cockpit AvionicsSuites
Embedded Virtual Training
Canada’s Department of National Defence, Hawker Beechcraft Corp., Korea Aerospace Industries (KAI), US Navy, Sikorsky, US Army, USAF, Westland, Pilatus, Aermacchi, Chilean Air Force (FACH) , Dubai Air Wing.
4.3 Custom Electronics
Display components and panels
Hybrid microcircuits
Power supplies
Junction boxes
Airbus, Rockwell Collins, L3, Major aerospace companies
Products / services Main customers
Cockpit avionics upgrades and systems integration
Flight Management Systems
GPS sensors for ground station and airborne use
Satellite communications (Satcom) antennas
Enhanced vision systems & software applications
Electronic flight bags & software applications
Head-Up displays
Airbus, Air France, Austrian Air Force, Boeing, Bombardier, Corsair, Dubai Air Wing, Eurocopter, Honeywell, Korean Air Line, Japan Air Line, KLM, Lufthansa, Qantas, Saudi Arabian Airlines, Singapore Airlines and many other major OEM and airlines.
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4.4 Repair and Overhaul Program
The Repair and Overhaul Services department provides for the repair and modification of all CMC Electronics’ aviation products. CMC Electronics is the only BAE SYSTEMS recognized independent maintenance repair facility in North America for the repair and servicing of SECUs (Spoiler Electronic Control Unit).
For its Canadian facilities CMC Electronics holds an Approved Maintenance Organization (AMO) approval under Transport Canada (TC), Canadian Aviation Regulations (CAR) chapter 573, EASA 145 and Russian FAVT certificate FP145. The Maintenance release form provided is Form 1.
The customer group supports civil and military aviation equipment and systems including:
Global Positioning Systems (GPS)
Flight Management Systems (FMS)
Airborne Satellite Communications
SATCOM - Antenna Subsystems
Cockpit Management and Display Systems
Microwave Landing Systems (MLS)
Engine Instrument Display Systems
Doppler Navigation Systems
Cabin Display Systems
Enhanced Vision Systems (EVS)
Electronics Flight bags
GPS and LORAN Navigation Systems
SECU
4.4.1 Return Procedures Material Authorization (RMA)
In order to facilitate tracking the customer should request a Return Material Authorization (RMA) number prior to the return of the failed equipment to CMC Electronics or provide notice of incoming equipment by fax or e-mail, stating carrier and waybill number, details of equipment/failure and purchase order number to your Order Administrator.
When contacting CMC Electronics Customer Support for RMA number and/or service requests, the following information regarding the equipment and the aircraft is required:
Complete part number of faulty equipment
Complete serial number of faulty equipment
Aircraft type and tail number
Report discrepancy/malfunction of equipment
Service requested (Repair, Modification, Exchange, Loan/Rental)
Ship to address
Equipment covered by Warranty?
Purchase order number (billing address)
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4.4.2 Warranty
CMC warrants its equipment against defects in design, material or workmanship, which, under proper use, appear in the equipment or parts thereof, provided that the equipment is returned to CMC, transportation prepaid, within the specified warranty period.
4.4.3 "Out-of-Warranty" Equipment Repairs and Related Rentals
For "Out-of-Warranty" repairs, rental equipment may be available. Please check with your Administrator for rates and conditions.
4.4.4 Firm Fixed Repair Prices
CMC Electronics Inc. maintains a list of "Firm Fixed Repair Prices". Firm fixed repair prices are applicable to equipment that has failed as a result of normal operational use. Such equipment must be structurally sound and complete. These are applicable to post-warranty repairs performed at the CMC Electronics Inc. factory.
4.4.5 Web site link:
http://www.esterline.com/avionicssystems/en-us/overview.aspx
4.5 Subcontracting
CMC does not subcontract any processes including packing, which are performed on site, and has its own in-house shipping/receiving area.
Notes: * CMC offers conformity certificates or regulatory release certificates as
necessary. * CMC uses only new traceable certified parts that are not refurbished in the
design, manufacturing or R&O of its products.
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5. MAIN SUPPLIERS LIST
CMC has more than one thousand suppliers; the supply chain is distributed as follows:
U.S. 31%, Canada 62%, Europe and Asia 6% and approved suppliers are estimated at over 500 for production.
A list of main suppliers can be consulted on site if needed.
6. FINANCIAL DATA
CMC Electronics Holdings Inc.'s D&B rating was formerly 5A2 (D&B ref 20-213-5604). Now that CMC is a wholly owned subsidiary of Esterline Technologies Corp, D&B uses the rating of the parent company Esterline which is also 5A2 with a Financial Stress Class of 3 and a Credit Score Class of 1 (lowest risk).
The bank of CMC Electronics is: TD Canada Trust, 3131 Boul. de la Côte-Vertu, Saint-Laurent, Quebec.
7. CMC QUALITY SYSTEM
CMC has developed and implemented a Quality Management System to demonstrate that it is continuously maintained for effectiveness and process improvements in accordance with the requirements of ISO 9001:2008, of AS9100. The internal audit process is compliant to ISO 19011. Also implemented an Environmental Management System certified to ISO 14001 for our Canadian sites.
CMC controls monitors and controls the shelf life of all materials having an expiry date.
No exclusions are taken because all requirements of the ISO 9001:2015 and AS9100 Rev. D apply.
The Quality Management System documentation is kept current and readily available to auditors and customers.
7.1 New product or product modification
Each time CMC builds a product for the first time, an FAI is performed per AS9102.
The product part number is changed when the company introduces modifications that affect the form, fit, function or interchangeability of the product.
Engineering change procedures are documented to notify customers by e-mail or written letter, of any changes to our products that may affect performance, quality, dimensions or reliability as required. CMC has Configuration Management and changes that affect product are also documented by SIL or SB.
7.2 Quality Control
CMC uses a number of techniques to verify its suppliers such as on-site surveys, audits and performance history. All information concerning accepted or rejected product quantities from suppliers is recorded upon receipt. The Quality records are maintained for a period of 10 years.
CMC pays special attention to controlling the revision status of Airworthiness data and ensures that the latest revision date is upheld.
CMC maintains ‘’real time’’ SPC charts for processes that are subject to SPC and can share this information with customers. The statistical sampling procedures are based on ANSI/ASQC Z1.4.
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7.3 List of pertinent approvals certificates (See copies in appendix )
Type of certificates Number Organization
ISO 14001:2015 EMS 584897 BSI
AS 9100 Rev. D FM 63598 FM76124
BSI ISO 9001-2015
ISO 14001:2015 EMS 584897 BSI
RTCA/DO-200A File 5012-N1 Transport Canada
DAO (Design Approval Organisation) 03-73 Transport Canada
MIL-PRF-38534 03-73 DSCC
AWM 561-Manufacture/certification 03-73
Transport Canada CAR 573.0-Maintenance
EASA 145. 7022 EASA
NADCAP for electronics AS7003 PRI
Russian certificate FP145 2021130007 FAVT
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8. CONTINUOUS IMPROVEMENT
CMC utilizes a variety of continuous improvement programs, techniques, processes and tools, including Lean and Six-Sigma.
8.1 Understanding the organization and its contexts
CMC’s philosophy is to pursue niche markets in which products of the utmost quality, highest reliability and most innovative functions are required. CMC adheres to the Esterline Operating System:
The Esterline Operating System is how we will deliver value to our customers. Our cultural framework – The Esterline Way – merges our values & principles, people philosophy, and operating approach to outline how we will achieve success using both operational excellence and our mission-critical cultural characteristics.
Our leaders are committed to our core values of reliability, respect, integrity, and compliance. They behave according to those principles and support driving all aspects of the Esterline Operation System to create the greatest level of improvement and success for all employees and for the future of our company and products.
8.2 Lean/Six-Sigma
CMC uses Lean / Six-Sigma methodology (DMAIC: Define, Measure, Analyze, Improve and Control) to reduce variations in products, and design, manufacturing and transactional processes. The prime focus is defined by the needs of internal and external customers.
The Six-Sigma program includes the following tools and techniques: Kaizen, 5S, Poka Yoke, Process capability, DFSS, VSM, DOE, Lean Manufacturing, SMED, SPC.
CMC’s Six-Sigma trained personnel consists of: 220 Green Belts (40 hours of training), and 29 Black Belts (total of 20 days of training).
All training modules are available on the CMC intranet, which is designed to give easier access to materials, tools, project examples, resources, and other general information concerning Six Sigma and Continuous Improvement.
9. HOUSING, FACILITIES AND SECURITY
CMC has facilities of adequate size to house all necessary tools, equipment, material and parts to perform contracted work. All parts and equipment, including those of the customers, are properly packaged, identified and stored to protect from damage, contamination, fire and theft.
The storage and work areas are separated, both are environmentally controlled, meet the industry standards and comply with customers’ and/or government imposed requirements.
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CMC has a security system and a fire protection system including sprinklers.
All electronic data are externally backed-up daily.
CMC’s Canadian operations hold a certificate of the Canadian control Good Programs (appendice 8) and the Sugar grove facility is DDTC (Directorate of Defense Trade Contracts) is registered under number M-8349.
10. OPERATION AND TEST CAPACITY
To effectively manage the company’s capacity, CMC uses a BAAN IV ERP system to monitor the overall capacity of each manufacturing department. Standard times are assigned for each and a rough capacity analysis is performed by the master planner in the planning group. This is a dedicated group for this type of facility. The CRP is then analyzed by the supervisor, who verifies the data pertaining to each manufacturing area. Subsequently, adjustments are made to pull-in or push-out production activities in line with customer requested date.
CMC operates approximately 8 hours per day, with a limited evenig shift, and the current operational capacity is about 50%.
The plant shut down is normally scheduled for 3 weeks in July-August and 1 week between Christmas and New Year’s Day.
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11. CERTIFICATES - CLICK HERE TO VIEW THE FOLLOWING CERTIFICATES
11.1 The Canada Border Services Agency
11.2 ISO 14001 Environmental Management System
11.3 Certificate of approval AMO (maintenance) - Transport Canada
11.4 Certificate of approval Manufacture - Transport Canada
11.5 ISO 9001 and AS9100
11.6 Certificate of Canadian control Goods program
11.7 EASA
11.8 NADCAP for electronics
11.9 Processing Navigation data – FAA – Transport Canada
11.10 Capabilities list
11.11 MIL-PRF-38534 hybrid microcircuit certification (custom electronics)
11.12 Russian FAVT certificate FP145
11.13 Certificate CAAC (China)
11.14 Hong Kong Civil Aviation Dept
11.15 Certificate of appreciation DND A300 program