D1-9000 is the Boeing Company document that addresses their internal and supplier quality system and the approach to continuous improvement. D1-9000 establishes the following requirements for Boeing and their suppliers:
Basic Quality System
Advanced Quality System (AQS)
Supplier Quality Rating
Basic Quality System Requirements
Boeing and their suppliers are to establish and maintain written procedures and flow charts defining their quality control system. Product quality is the responsibility of engineering and manufacturing; quality control and quality assurance is to assist design and manufacturing to ensure product conformance.
Boeing periodically reviews internal and supplier procedures. The following list reflects the minimum elements that a supplier’s Quality Assurance function is expected to document and implement:
3. Manufacturing Quality Control
5. Drawings, Digital Media, and Specifications
6. Proprietary Designs
7. Procurement by the Supplier
8. Inspection Stamps
9. Measurement and Test Equipment
11. Inspection Methods
12. Functional Tests
14. Quality Audit Program
15. Authority and Responsibility of Boeing Quality Representatives.
Advanced Quality System (AQS)
The attached process flow for AQS reveals the major thrust for the Boeing AQS, i.e. the systematic reduction of variation in key characteristics (KC). Boeing may provide the key characteristics to their suppliers via specifications, control drawings, CAD/CAM, etc. or the suppliers may be responsible for providing the KC themselves.
The Control Plan is the essential document in identifying, tracking and recording KC, gage or measurement variation and process variation. A study of the AQS Process Flow indicates that appropriate selection of control charts is a necessary step in measuring and reducing variation. The function of the control chart is to:
1. Monitor the manufacturing system for stability.
2. Identify and remove assignable causes of variation, e.g. new operator, new material, etc. are assignable causes of variation. 3. Once the assignable causes of variation are removed, collect new measurements and determine the new control limits. 4. When only random causes exist, study the data to determine the contributors to the total variation, e.g. the 5 M’s - manpower, materials, machines, methods and measurement. 5. Correlate sources of process variation with key characteristics. 6. Predict and achieve required process capability (Cpk).
AQS Tool Reference Guide (from the Boeing Company’s D1-9000) |AQS Tool |Used for these tasks | |Teams |Teams should be used whenever possible during problem-solving activities and throughout the| | |AQS process, e.g., determining key characteristics and identifying sources of variation. | | |The tools listed below are most effective when done in a team environment; particularly | | |when brainstorming, doing risk analysis, cause & effect diagrams, process flow charts, and | | |designed experiments. | |Brainstorming |Generating ideas from a group | | |Establishing potential key characteristics | | |Identifying potential sources of variation (either common cause or special cause) | |Pareto Analysis |Displaying relative importance of each...