Course overview
This 2-day course covers in detail everything that is needed to develop, document and implement AS9100 and AS13100 conforming processes to address Counterfeit parts, Product safety and Safety Management Systems (SMS) – plus the legislation and regulations associated with Conflict minerals (3TG).
Counterfeit parts, Conflict minerals and Product safety pose a clear and present danger. TEC’s course will ensure that your people understand the serious threats, and are empowered to implement the necessary strategies and processes to avoid and/or mitigate the hazards.
The certification bodies will be auditing these topics as part of their AS9100 re-certification and routine surveillance audits – so be fully prepared!. The course is highly interactive and includes many team exercises, scenarios and quizzes.
Course details
Counterfeit parts (Day-1)
What the international press have been saying!
Understanding how counterfeit parts arise!
What are counterfeit parts?
Differentiating between ‘Counterfeit’, ‘Fraudulent’ & ‘Suspect’
Sources of terminology definitions
Counterfeit part – formal terms and definitions
Team exercise – identifying possible counterfeit parts
Most commonly counterfeited ‘non-electronic’ parts
Class quiz – part terminology in your own words
Impact of counterfeit parts
Why is this issue so difficult?
What are the sources and consequences of counterfeit parts?
Recycling is increasing on a global basis
Team discussion – personal experience of counterfeit parts
Standards and their applicable requirements for QMS processes relating to counterfeit parts
Identifying applicable standards and their interrelationships
AS5553:2016 Rev B
IEC TS 62668-1:2016
Def Stan 05-135
AS9100:2016 Rev D
Fundamental AS9100:2016 Rev D requirement
Fundamental AS5553:2016 Rev B requirement
Team exercise – understanding AS9100 and AS5553 requirements
Class quiz – have you considered all types of matériel?
Assessment of an organization’s prevention/control of counterfeit matériel QMS process
AS/EN/JISQ 9100:2016 (Rev D) Auditor Guidance Material
Turtle Diagram – prevention/control of counterfeit matériel process
Top-level ‘gap analysis’ check-list
Individual exercise – AS9100:2016 compliance & CB ‘expectations’
Review of practical implementation strategies
Focusing implementation strategies on applicable requirements
IEC TS 62668-1:2016 – minimum avionics OEM requirements
Elements of implementation strategies
Personnel (awareness) training
Establishing anti-counterfeit awareness training
Team exercise – training in awareness and prevention of counterfeit parts
Application of a parts obsolescence monitoring programme
The need for a parts obsolescence monitoring programme
Establishing a parts obsolescence monitoring programme
Individual exercise – parts obsolescence monitoring programme
Controls for acquiring externally provided product from original or authorized manufacturers, authorized distributors, or other approved sources
Tightening supplier evaluation, selection and monitoring
Proactive risk identification/mitigation
Procurement risk mitigation flow diagram
Minimize risk of counterfeit matériel – use authorized suppliers!
Purchasing process
Purchasing information
Individual exercise – purchasing process & purchasing information
Requirements for assuring traceability of parts and components to their original or authorized manufacturers
Understanding the requirements for traceability
Reasons for loosing part/component (matériel) traceability
Team exercise – compliance/gap analysis of matériel traceability
Compliance/Gap analysis results
Verification and test methodologies to detect counterfeit parts
Parts testing processes
Tests and inspections for counterfeit EEE/matériel detection
Team exercise – tests and inspections methodologies
Monitoring of counterfeit parts reporting from external sources
Preventing the re-entry of counterfeit matériel into the supply chain
Team exercise – preventing the re-entry of counterfeit matériel into the supply chain
Quarantine and reporting of suspect or detected counterfeit parts
Quarantine and reporting of suspect or detected counterfeit parts
Team exercise – quarantine and disposition of counterfeit matériel
Dealing with suspect or confirmed fraudulent/counterfeit matériel
Class quiz – dispositioning/reporting of counterfeit matériel
Conflict minerals
What are ‘conflict minerals’?
Identifying conflict minerals and their source(s)
Supply chain risk and due diligence
The risk of supply chain ‘contamination’ with “three Ts & G”
Understanding due diligence in practice
Class quiz – potential for ‘conflict minerals’ in your organization
Legislation and regulations
Recent legislative and regulatory initiatives
OECD Due Diligence Guidance booklet
EU regulation 2017/821
Understanding ‘due diligence’
Private study – review of relevant legislation and regulations
Review of practical implementation strategies
The 5-steps of the OECD Guidance – EU article numbers
Actions to address the 5-steps
Need for a supply chain policy
Need for a supply chain policy
Product safety (Day-2)
Understanding the need for product safety
Diversity of A|D|S parts and their global supply chain
Global aircraft manufacturers commitment to product safety
Product safety demands the mitigation of ‘hazards’ and ‘risks’
Overview of AS9100:2016 product safety requirements
Definitions taken from ISO 9000:2015
Team exercise – product safety communication and awareness
Understanding the terminology use to describe parts and their characteristics
Definition of a product
Understanding product terminology ‘variants’
Product ‘characteristics’ requirements
Team exercise – identifying your organization’s terminology
Understanding the terminology and requirements relating to product safety?&
Product safety – AS9100:2016 definition and requirements
Product characteristics – Critical items
Product characteristics – Special requirements
Product characteristics – Key characteristics
Identification of items, requirements and characteristics
Team exercise – explaining the terminology
Understanding the relationship between AS9100:2016 requirements relating to product safety
Product safety considerations throughout the product lifecycle
The “V” model
When/how are product safety requirements determined/used?
Team exercise – product safety-related QMS processes
Extracts from AS9100:2016
Identification of items/characteristics related to product safety
Team exercise – items/characteristics related to product safety
Identifying potential hazards
Requirements for processes/controls to address product safety
Class quiz – more product safety/hazard related aviation terminology
Product safety ‘cycle’: identification – quantification – mitigation
Sources and categories of hazards
Tools and techniques for hazard identification
Brainstorming – basic approach and ‘variants’
Bow-tie diagram – identification of hazard causes/consequences
Hazard log – basic template (organizational knowledge)
Other methodologies for hazard(s) identification
Evaluating (quantifying) and ranking hazards and risks
Evaluating hazards and risks (severity and occurrence)
Risk ‘tolerability’ matrix (aka ‘heat’ map – S & O)
Team exercise – inadequate maintenance by personnel
Determining potential causes of hazards
Identifying hazard causes from ‘different perspectives’ (6-M)
Understanding the 6-M categories
Investigating the role of ‘human factors’
The dirty dozen
Determining basic cause(s) leading to the event
Team exercise – BA 5390 incident
Safety management systems (SMS)
Defining a Safety Management System (SMS)
1 - Safety policy
2 - Safety Risk Management
3 - Safety assurance
Interfaces between 2- SRM and 3- SA
4 - Safety promotion
Relationship between the SMS and the QMS
Prioritizing product safety – minimizing hazards
Sequence of the steps to identify and mitigate hazards
Quantifying the ‘before situation’ – PFMEA & RPM
Mitigating the effects of potential hazards – ‘after situation’ RPN
Team exercise – QMS compliance/gap analysis of product safety
Product safety ‘environment’, communication and awareness training
Product safety ‘environment’ – just culture and ethical behaviour
Summary of product safety training goals
Training plan and considerations
Product safety communication
Effective communication and awareness training guidelines
Team exercise – empowering personnel in product safety
Understanding the ‘operator view’ – pressure vs. procedure
Product safety policy and safety performance KPIs template
Product safety policy – template
Safety Policy (example)
Safety performance KPIs template
Final comments and questions
Who should attend
Top management teams, Quality managers, Accountable managers, Quality engineers and all levels of management responsible for developing, documenting, implementing and maintaining AS9100:2016 Rev D conforming processes to address Counterfeit parts and Product safety and meet OECD legislation and EU regulation 2017/821 concerned with Conflict minerals.
Deliverables & benefits
Counterfeit parts and Product safety are mandatory requirements of AS9100:2016 Rev D. Conflict minerals are the subject of international legislation and EU regulations. This course is specifically aimed at both (i) Make-to-print, and (ii) Design-and-make organizations – and also addresses the requirments in AS5553:2016 Rev B, IEC TS 62668-1:2016 and ARP632.
All aerospace/defence organizations need to understand how they must develop, implement and maintain appropriate processes to effectively address counterfeit parts, product safety and conflict minerals.
TEC's practical 2-day course will empower organizations to demonstrate full conformity with AS9100:2016 requirements, meet aerospace customer expectations and comply with legislation and regulations.
This course is classified as ‘structured’ for continuing professional development (CPD) purposes by the CQI/IRCA. It contributes 16-hours to the required 45-hours of appropriate CPD for QMS Lead Auditors.