For other product types, the aerospace Design Checklist Non-Electromechanical Devices AS1900 Template should be completed and evaluated. AS1080-6 DESIGN CHECKLIST FOR NON-ELECTROMECHANICAL DEVICES covers aerospace product specification, performance factors, accuracy, range, and more. Comment abbreviations such as “U” for unsatisfactory and “NI” for needs improvement may be used to save time while completing the Aerospace Checklist for Non-Electromechanical Devices.
Review results should be documented in report form and signed by Management personnel as complete and accurate. All changes made as a result of design review findings should be documented and include conclusions and recommended follow-up, then disseminated to appropriate organizational functions, including management in a timely manner. The Product Development Team should keep all such reports with the Design Review Checklist.
The Aerospace Design Review Checklist AS9100 Template should be completed, appropriate to the product. The design review should identify and anticipate problem areas and inadequacies, and initiate corrective actions to ensure that the final design and supporting data meet customer requirements. The Aerospace Product Development Team should refer to AS1080-4 DESIGN REVIEW when periodic project design reviews are conducted.
The Aerospace Design Review Checklist includes the following:
Physical characteristics, constraints, and aesthetic specifications;
Safety needs of the user, environmental compatibility, and the need for fail-safe characteristics;
Considerations of unintended uses and misuses;
Compliance with regulatory requirements and industry standards;
Labeling, including warnings, identification and traceability, operating and maintenance instructions; and more.
At the completion of each Design and Development activity, a formal design review of the results should be performed and documented for future process assessment, which then become the basis of design lessons learned for design process improvement. Design reviews should be objective, unbiased examinations by appropriately trained personnel and should also include those that were not directly involved in that design activity, for objectivity.
Internal and external aerospace documents should be logged in the AS9100 Document Control Database Template by Document Control in order to assist in tracking all distributed documents that are critical to quality, before being distributed to approved/interested parties.
AS1000-2 DOCUMENT CONTROL DATABASE should contain, at a minimum, the following information for each controlled document:
AS9100 Document number;
Aerospace Document title;
Current revision number/ID/level of the document;
Effective date; and
Document Control should distribute (or limit distribution of electronic) documents only to locations shown on the Aerospace Document Control Database. Any previous versions of documents should be removed from work areas as new revisions are released. In the case of electronic document distribution and control systems, access permission for any previous version must be withdrawn or denied.
Document Control should maintain a file on each aerospace document; current and previous (retired or obsolete) Master documents may be retained in this document file only. When previous versions of documents are no longer required, Document Control should physically destroy or electronically purge them as per the AS9100 Document Control Procedure AS1000.
To submit a change or to request a new document, the requestor should fill out the Document Request AS Template and submit it to his/her Department Manager. After reviewing the request, the Department Manager should submit AS1000-1 DOCUMENT REQUEST and any attachments to the Quality Assurance Manager, who should review the request to ensure the document conforms to the QMS. The Aerospace Document Request Template covers date, request #, description of problem, solution recommended, and more.
If the Quality Assurance Manager finds the requested document (change) does not conform to the QMS, the Quality Assurance Manager should return the AS1000-1 and attachments to the Department manager with an explanation (e.g., what is needed to make the document conform). If the requested document is determined to conform to the QMS, the Quality Assurance Manager should determine who else needs to review the new/changed document (e.g., the originator is not involved with the process the document pertains to) and submit the form, with attachments, to those individuals for their review and approval.
Upon receiving the necessary approvals, the Quality Assurance Manager should forward the original Request Template and attachments to Document Control. Document Control should update the document and generate a new Master document. Note that flow diagrams, engineering drawings, and other documents generated outside the company (e.g., supplier blueprints, industry standards) are to be submitted to Document Control with a Document Request AS Template.
The Human Resources Manager uses the Employee Competence Matrix AS9100 Template to screen aerosapce applications and resumes to select candidates with the appropriate competencies for positions to be filled. AS1040-1 COMPETENCE MATRIX organizes positions based on necessary education, experience, knowledge, and skills. When later developing a training plan, information needed regarding competency can be taken from the Aerospace Competency Matrix.
Hiring supervisors and managers interview candidates to identify and select candidates who possess the minimum competencies required for the position. The Human Resources Manager may verify aerospace application or resume information of the final candidates by checking references or previous employers. If the best candidate does not have the minimum competence required, the hiring manager may arrange for training or other actions, as appropriate, to satisfy the requirements for the position.
The hiring supervisor or manager should evaluate the effectiveness of training or other action taken, in accordance with the Job Descriptions procedure. Training and subsequent evaluation will be based on behavioral objectives which provide concrete evidence of competence. The employee’s supervisor or manager should, with the assistance of the Human Resources Manager, take appropriate action to modify the aerospace training program or provide additional training if the evaluation shows the training was ineffective.
The Aerospace Employee Development Plan AS9100 Template helps in developing a training program for the critical to quality skills demanded by the aerospace industry. The Human Resources Manager, in conjunction with the work center supervisor/manager and the employee in question, should develop and maintain a training plan for each employee. AS1040-2 EMPLOYEE DEVELOPMENT PLAN covers employee information, course date, competency, development actions, and more.
HR and Departmental management should annually review the aerospace quality training needs of all departments in order to maintain an updated company training and development plan. Training and development needs may be identified through performance evaluations, quality assurance processes, or company goals and objectives. The survey will identify weaknesses that may be resolved through staff training and development.
HR should periodically compare every employee’s actual training record with his or her Aerospace Development Plan Template to ensure that the employee is making suitable progress toward their individual competence and training goals. Crucial to any evaluation or review of the training and development function is the clear understanding and documentation of the degree to which the company objectives for providing training and development for its employees are effective and have been achieved.
The HR Manager should ensure that the training and development program is effective at meeting the stated objectives and producing the desired results.
The Aerospace Employee Group Training Record AS9100 Template helps HR maintain a record of each employee’s job-related training. The HR Manager, with the assistance of various Department Managers, should develop an aerospace training and development plan that supports and advances the company’s business strategy, addresses long and short-range quality needs, clearly states objectives, and directly relates to the company’s mission and goals. The AS9100 Employee Group Training Record Template is used used to collect data to determine the effectiveness of traning. AS1040-3 EMPLOYEE GROUP TRAINING RECORD covers course title, course date, employee name, and more.
Company employees whose work affects the quality of company products should be evaluated periodically (this should be done annually, at a minimum) with regard to QMS competence and training. Records of such evaluations should be kept in the employee’s file. HR should maintain a record of every employee’s training (such as the Aerospace Group Training Record), education, skills, and experience in his/her personnel file. Employee training records should be kept in a file separate from personnel records, as privacy and confidentiality requirements for personnel records do not necessarily apply to training records.
Employee Group Training Record AS9100 Template Details
Ideas for new aerospace products, services, or processes should be submitted to the Engineering Manager on an AS9100 Engineering Action Request Template. Ideas for products or processes may originate inside the company – management, the Marketing Manager, and the Engineering Manager are among the areas where ideas may be generated, but a well-run company will entertain ideas for products or services wherever they come from. Ideas will often come from outside the company – occasionally, a customer will offer a suggestion. AS1080-1 REQUEST FOR ENGINEERING ACTION should contain an adequate description of the aerospace idea and the potential benefits to the company and its customers should be explained.
If possible, aerospace product requirements and objectives should be stated and should be specific. Any supporting documentation (e.g., spreadsheets, diagrams, charts) providing detailed information and clarifying concepts and issues should be attached to the Aerospace Engineering Action Request before submission. The Engineering Manager should assign a project (request) ID for tracking purposes and enter the AS1080-1 and any attachments in a Product Development file or database. The Engineering Manager should track the status of each development project and provide a status report to Top Management and other interested parties.
Status reports should be provided on a periodic basis (as input to management review, for example) and at the end of each phase of the engineering process. The Product Development Team should review design objectives and requirements, provided by the aerospace customer. If these customer requirements are not provided with the aerospace AS9100 Engineering Action Request Template or the customer requirements provided are unclear or incomplete, one of the Product Development Team should contact the customer for clarification or more information.
The Engineering Change Notice AS Template should be complete upon evaluating the change, design, development, testing, and authorization. The Engineering Manager should complete Part I of AS1090-1 ENGINEERING CHANGE NOTICE, obtain the appropriate authorization(s), enter the change in the Product Development file/database, and assign a change number for tracking, logging, and filing purposes. Verification and validation information for minor changes should be recorded in Part II of the Aerospace Engineering Change Notice.
The Engineering Manager should complete Part III after verification and validation is complete, to ensure all related documentation affected by the change is updated, as appropriate. The Engineering Manager should have overall responsibility for coordinating, scheduling, and executing documentation changes with Document Control. When documentation is updated, Document Control should purge or remove all originals and working copies of obsolete documentation from circulation.
A First Article Inspection Report AS Template may be required on some items (e.g., new parts, part revisions). If the company requires an Aerospace First Article Inspection Report, the Quality Assurance Manager should verify that the supplier’s FAI report addresses the company’s requirements using the AS1130-2 FIRST ARTICLE INSPECTION REPORT as a guide. If multiple part numbers are included in a shipment, each part will be segregated and handled (e.g., inspected, put into stock) according to applicable requirements.
The Quality Assurance Manager should periodically pull samples of incoming parts, components, materials, etc., to verify that the items conform to requirements and validate suppliers’ test reports and certifications. The Quality Assurance Manager is responsible for conducting detailed examinations of incoming materials, when necessary, and for recommending acceptance or rejection of goods to the Procurement Manager.
First Article Inspection Report AS Template Details
The Aerospace AS9100 Individual Training Record Template helps HR maintain a record of each employee’s job-related training. The HR Manager, with the assistance of various Department Managers, should develop an aerospace training and development plan that supports and advances the company’s business strategy, addresses long and short-range needs, clearly states objectives, and directly relates to the company’s mission and goals. AS1040-4 INDIVIDUAL TRAINING RECORD covers employee, job position, date, subject, and more.
HR should then periodically compare every aerospace employee’s actual training record (such as the AS9100 Individual Training Record Template) with his or her plan to ensure that the employee is making suitable progress toward their individual competence, skills, and training goals.
HR should maintain a training , education, skills, and experience record for every employee’s as part of their personnel file. Employee training records should be kept in a file separate from personnel records, as privacy and confidentiality requirements for personnel records do not necessarily apply to training records.
Individual Training Record AS9100 Template Details
Quality Assurance should use the Inspection Testing Checklist AS Template to inspect company products in accordance with requirements, to verify the quality and conformity of parts and gauge the effectiveness of the design, development, and production processes. The QA Manager should fill out AS1150-1 INSPECTION/TESTING CHECKLIST for the part to be inspected, based on inspection requirements, key characteristics, and assign the inspection. The QA Manager should include a detailed description/explanation of the inspection (see section 4 of AS1150-1) and attach relevant inspection records, etc., as needed.
Depending on the nature, composition, and complexity of some items – and possibly due to customer or other requirements – they will require inspection for the presence of foreign objects (Foreign Object Detection, or FOD). If FOD is required, this must be included on the Aerospace Inspection/Testing Checklist (see section 3, AS1150-1). The inspector should inspect the item (part, component, etc.) for conformance to all requirements stated on the AS1150-1, checking the box in the “I” (inspected) column after each requirement. If the inspector tests for conformance, the “T” (tested) column must be checked. If the item fails to meet a requirement, the inspector should indicate in the “Comments” section which of the listed requirements was not met (referencing the requirement number on the form) and include an explanation. The inspector/tester should sign and date the AS1150-1, indicating whether the part passed or failed inspection/tests, and submit the checklist to the QA Manager. The QA Manager should review the checklist with Production, to determine whether to continue with production.
Job descriptions should be prepared using the Job Description AS Template as a guide. Any unusual needs or requirements for the position should be added in a separate section. AS1030-1 JOB DESCRIPTION covers job title, effective date, department, summary of functions, and more. The Aerospace Job Description Template must be signed by the department manger, HR manager, and Senior Management.
Hiring managers should be responsible for initiating drafts or changes to existing job descriptions. Whenever practical, supervisors should interact with other employees – managerial and non-managerial – when developing or reviewing descriptions in order to better ensure accurate, clear, and meaningful job descriptions. The next higher management level should approve job descriptions prepared by their subordinate hiring managers. The Human Resources Manager should communicate completed job descriptions to hiring managers and their superiors.
The Human Resources Manager should periodically review job descriptions to: determine if those descriptions accurately reflect the company’s short- and long-term needs (e.g., industry/technological advances, competitiveness); and ensure that job descriptions continue to meet company and regulatory requirements (e.g., Americans with Disabilities Act, Fair Labor Standards Act, Occupational Safety and Health Act).
The Management Review Meeting Record AS Template is used by the Quality Management Representative (QMR) to keep a record of each management review, in accordance with the requirement of AS 9100. The QMR may record the minutes of all such meetings, to add to the management review record. AS1020-1 MANAGEMENT REVIEW MEETING RECORD should, at a minimum, consist of:
Time, date, and location of the meeting;
An attendance log; and
The meeting agenda.
The purpose of the management review is to review the company’s QMS and ensure its continuing suitability, adequacy, and effectiveness, and to assess opportunities for improvement and the need for changes to the system, including the Quality Policy and related objectives. The Aerospace Management Review Record Template covers action items and who they are assigned to, minutes/decisions, inputs, outputs, and more.
Input to the management review meeting should include, but need not be limited to: results of audits, customer feedback, reports on the performance of the QMS and the need, if any, to improve it, and more. Output of the management review meeting should include all decisions and actions relative to: improving the effectiveness of the QMS and QMS processes, product improvement related to customer requirements, and resource needs.
Management Review Meeting Record AS Template Details
The Material Return Notice AS Template covers date, quantity, part number, reason for rejection, and more. In the event of any damage, deterioration, of unsuitability of customer-supplied items, Receiving should process such items in accordance with AS1230 CONTROL OF NONCONFORMING PRODUCT. An AS1170-1 MATERIAL RETURN NOTICE should be prepared with the applicable information. The Aerospace Material Return Notice should then be returned to the customer with the nonconforming items and other related paperwork (e.g., packing slips).
If, for any reason, there is a shortage or loss of items discovered after the original Receiving and Inspection report is prepared, the Inventory Control Manager should issue a written report on the discrepancy, in accordance with AS1230 CONTROL OF NONCONFORMING PRODUCT, and notify the customer of the loss. The Inventory Control Manager is responsible for identifying items as coming from or belonging to the customer, keeping those items segregated from other production materials/tools, and maintaining control of customer inventory.
The person identifying the aerospace nonconformance completes the top section of the AS9100 Nonconformance Report Template. AS1230-1 NONCONFORMANCE REPORT covers part number, vendor, nonconformity, rework/repair instructions, and more. The person filling out the Aerospace Nonconformace Report should sign and forward the form to Quality Assurance, the Production Manager, and/or the Procurement Manager, as appropriate, so that proper disposition of the material may be determined. Engineering may be asked to assist in determining material disposition.
The Production Manager, and/or the Engineering Manager, and/or Purchasing, and Quality will review the nonconforming items and identify the disposition. Persons determining/authorizing disposition should sign the AS1230-1 in the appropriate area. For items that can be reworked or repaired, Engineering and Production should complete and authorize rework/repair instructions and ensure their correct implementation. Reworked or repaired items must be re-inspected in accordance with company aerospace inspection procedures or work instructions.