Course overview
This 3-day IAQG-approved course provides personnel with Aviation, Space and Defence (ASD) industry specific knowledge and demonstrable understanding of the principles, requirements, controls and application of the ASD topics.
IAQG approved course & examination (TCSS 002)
The requirements contained in IAQG Training Course Specification Sheet (TCSS 002) are met in full (24 CPD hours credit).
this Face-to-Face (Instructor Led) course, and the associated written Exam, is intended for existing or prospective AEAs and AAs to support the scope of their certification capabilities
The course includes detailed introductions of the principles, requirements, controls and application across the ASD industry.
Course planning and delivery in full conformity with IAQG Course Planning and Delivery Requirements (TCSS 005)
Course details
Introduction and Delegate Workbook
Classroom-based course instructions
Course syllabus and timetable
Exercise: review the Delegate Workbook
Advanced product quality planning (APQP) & Production part approval process (PPAP) – AS9145
What is APQP?
What is PPAP?
PPAP submission/re-submission
APQP & PPAP applicability and application
Product Development Process (PDP)
AS9145 and related ASD standards
AS9145 quality tools/techniques and conformity
The APQP phases
Product Breakdown Structure (PBS)
APQP ‘cascade’ through PBS & PDP
Benefits of, and Obstacles to, APQP deployment
Knowledge checklist
4.1 (a) Advanced product quality planning (APQP) & Production part approval process (PPAP) – AS9145
4.1 (b) Advanced product quality planning (APQP) & Production part approval process (PPAP) – AS9145
4.1 (c) Advanced product quality planning (APQP) & Production part approval process (PPAP) – AS9145
Change control
Design activities, design authority and configuration
AS9116 requirements for Notice of Change (NOC)
Notice Of Change (NOC) submittal process
Change proposal information and change types
NOC data and NOC form
Change impact analysis tool (IAQG template)
Knowledge checklist
1.11 Change control
Containment, cause analysis, and corrective action
AS9100 and ARP9136 requirements
The 8D process
The 8D stages and ‘deliverables’
The 8D steps
Visualizing the 8D steps and timelines
Case Study – background
D0 – start immediate containment and define problem
D0 – Illustration
D1 – appoint the 8D practitioner (i.e. facilitator) who establishes the team
D1 – Illustration
D2 – define and quantify the problem
D2 – Illustration
D3 – complete, optimize and verify interim containment actions
D3 – Illustration
D4 – determine and prove root cause(s) including ‘human factors’
D4 – Illustration
D5 – define and select permanent corrective actions
D5 – Illustration
D6 – implement and validate permanent corrective action(s) – check their efficacy
D6 – Illustration
D7 – prevent recurrence of the problem and promulgate the solution
D7 – Illustration
D8 – recognise and congratulate the team
D8 – Illustration
The 8D Report
Knowledge checklist
4.3 (a) Containment, cause analysis, and corrective action
4.3 (b) Containment, cause analysis, and corrective action
Configuration, identification and traceability
Defining configuration and configuration management
ISO 10007:2017 ~ Quality management – Guidelines for configuration management
Applicable terms and definitions
Importance of configuration and configuration management
AS9100 configuration management requirements
Objective of configuration management
Configuration management process
Principles and functions of configuration management
Configuration management functions and principles
Configuration management application in the product life cycle
Program life cycle configuration progress
Configuration management building blocks
Configuration management tools
Part identification and traceability
Configuration item identification numbers
Identification (marking) of aerospace parts
Part marking in the aerospace sector
Defining product traceability
Knowledge checklist
1.2 Configuration, identification and traceability
Critical items and Key characteristics
Interrelationship of special requirements, critical items and key characteristics
Special requirement (SR)
Critical Item (CI)
Key Characteristic (KC)
AS9103 ~ Aerospace Series – Quality Management Systems Variation
Management of Key Characteristics
Defining statistical control
Establishing statistical control
Sequence: statistical control ~ process capability
Process ‘capability’ determination
AS9103 – Process Control Document (PCD)
Ongoing monitoring of KCs
Monitoring using the 8 industry standard tests
Knowledge checklist
1.12 (a) Critical items and Key characteristics
1.12 (b) Critical items and Key characteristics
Design and development
Product development process (PDP)
Product design and development process
The DfM, DfA and DfMA approaches
Design Failure Mode & Effects (DFMEA)
Design verification plan and report
Design validation testing
Knowledge checklist
2.1 Design and development
First article inspection (9102)
Purpose of a FAIR
FAI planning activities, requirement and steps
Status of a FAI and partial FAI requirements
The FAIR forms and their contents
Control of FAI records and variable/attribute data
Knowledge checklist
1.1 (a) First article inspection (9102)
1.1 (b) First article inspection (9102)
External provider approval and control
Understanding AS9100 ‘external provider’ requirements
Approval status and performance monitoring
Demonstrating products/services meet requirements
Delegated verification and test reports
Work transfer requirements
Knowledge checklist
1.3 External provider approval and control
Human factors
Human factors in aerospace/defence
Identifying possible human factors
Identifying and verifying probable human factors
Countering human factors – remove blame, boost results
Designing human factors training programmes
Knowledge checklist
2.3 (a) Human factors
2.3 (b) Human factors
Foreign object damage/debris (FOD) prevention program
FOD – terminology, definitions and consequences
FO and the escalation to FOd resulting in FOD
The AS9146:2017 standard and requirements
The NAS 412 guidance document
Program Management (4.1)
Operations (4.2) and Area designation (4.3)
Examples of signage and area designation
Examples of signage/area designation and entry permissions
Training and personnel access (4.4) and Product protection (4.5)
Housekeeping and clean-as-you-go (4.6) and consumables, hardware, and personal items accountability and control (4.7)
Tool accountability and control (4.8)
*Knowledge checklist
2.4 (a) Foreign object damage/debris (FOD) prevention program
2.4 (b) Foreign object damage/debris (FOD) prevention program
Material handling and preservation of products
AS9100 requirements for material handling and preservation of products
Minimum requirements for product preservation
Knowledge checklist
1.4 Material handling and preservation of products
Nonconforming material management
AS9100 requirements for nonconforming product containment and disposition
AS9100 requirements associated with the scraping of products
AS9100 requirements for responding to nonconformities
Knowledge checklist
*1.5 Nonconforming material management
Operational risk management
Identification of operational risks
Proactive management of operational risks
Concepts of risk management and Failure Mode & Effects Analysis (FMEA)
FMEA cross-functional team
PFMEA emphasis, scope, prioritization and plan
Process Flow Diagram (PFD)
Identifying sources of variation
The PFMEA ‘worksheet’ – detailed PFMEA risk analysis
Ranking risk – [S], [O] & [D]
Sources of FMEA Rankings & Action Priority (AP)
Risk evaluation and prioritizing actions
The PFMEA worksheet ‘sections’
Deploying action plans – improvement strategies
Revision control of PFMEA documents
Knowledge checklist
*1.6 (a) Operational risk management
*1.6 (b) Operational risk management
Special processes, including Nadcap
Defining ‘special processes’
Nadcap (Nadcap is not an acronym today!)
Nadcap – eAuditNet
Knowledge checklist
1.7 (a) Special processes, including Nadcap
1.7 (b) Special processes, including Nadcap
Sampling inspection or testing
Requirements and reasons for sampling
Sampling terminology
Consumer’s Risk vs. Producer’s Risk
OC (operating characteristic) curve
Engineering specifications vs. Consumer protection
Defining sampling inspection/testing and AS9138
Sampling inspection schemes
Example: Sampling inspection tables
Example: Sampling inspection tables (Minitab®)
C=0 sampling plans
Reasons for adopting C=0 sampling plans
Comparisons of sample plans types
Knowledge checklist
1.8 Sampling inspection or testing
ASD regulatory requirements
Fundamental aviation terminology
Aeronautical (type certificated) ‘products’
Aeronautical articles (parts and appliances)
Aeronautical ‘critical parts/components’
International Civil Aviation Organization (ICAO)
European Aviation Safety Agency (EASA)
Federal Aviation Administration (FAA)
CAAC – Civil Aviation Administration of China
Military Aviation Authority (MAA)
National Aviation Authority (NAA)
Hierarchy and structure of the ‘implementing rules’
Definitions of design, production and maintenance aeronautical organizations
Annex I – Part 21 ~ design-production coordination
Requirements for a production organization’s QMS
Form 1 – Authorised Release Certificate
Sources of additional information –
AMC, GM and ‘Easy Access Rules’
EASA eRules – aviation rules for the 21st century
Type Certificate (TC) – for aeronautical products
Technical Standard Order (TSO) – for aeronautical articles
Knowledge checklist
3.1 (a) ASD regulatory requirements
3.2 (b) ASD regulatory requirements
3.2 (c) ASD regulatory requirements
Safety management systems (SMS)
Defining a Safety Management System (SMS)
1. Safety policy
2. Safety Risk Management
3. Safety assurance
4. Safety promotion
Relationship between the SMS and the QMS
Knowledge checklist
1.9 Safety management systems (SMS)
Product safety
Understanding the need for product safety
AS9100 requirements relating to product safety
Understanding ‘hazards’ and ‘risks’
AS9100 product safety requirements
Assessment of hazards and management of associated risks ~ reactive
Assessment of hazards and management of associated risks ~ proactive
The “6M” method analysis of events affecting safety
Role of ‘communication’ and ‘awareness’
Creating a ‘just culture’ and ‘ethical behaviour’
The drivers and consequences of non-compliance
Definition and role of compliance training
Targets and methods of safety training
Air crash deaths – minuscule but don’t get complacent!
Knowledge checklist
2.3 (a) Product safety
2.3 (b) Product safety
Production processes and product verification/validation
Production processes – controlled conditions
Turtle diagram – visualizing controlled conditions
AS9100 requirements for production processes
Avoiding errors in the workplace
Instilling consistent use of work instructions
Product verification/validation
Product testing requirements
Knowledge checklist
1.10 Production processes and product verification/validation
Prevention of counterfeit parts
Definition of counterfeit parts
Counterfeit parts commodity types
Standards/Guides relating to counterfeit parts
AS9100 requirements
Personnel (awareness) training
Parts obsolescence monitoring programme
Controls for acquiring genuine product
Proactive risk identification/mitigation
Assuring traceability of parts and components
Reasons for losing traceability
Verification and test methodologies to detect counterfeit parts
Monitoring of counterfeit parts reporting from external sources
Quarantine and reporting of suspect or detected counterfeit parts
Knowledge checklist
Written Examination
2-hour written examination.
open book
70% pass mark
Who should attend
AEA (Aerospace Experienced Auditor) and AA (Aerospace Auditor) who need to demonstrate industry-specific knowledge.
Other aerospace quality professionals.
Deliverables & benefits
The purpose of this course is to provide ASD industry specific knowledge and demonstrate an understanding of the principles, requirements, controls and application of the topics detailed in the course syllabus (TCSS 002).
Your certificate of successful completion, indicating the examination/assessment criteria has been met, will be presented within 24-hours.