Programme overview
This 2-day course covers in detail everything that is needed to develop, document and implement AS9100-conforming processes to address Counterfeit parts and Product safety – 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.
Programme 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
- 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
Control methods – detecting hazards and root causes
- Identifying ‘control methods’ – the ‘Bow-tie’ methodology
- Understanding hazard/cause controls and ‘rankings’
- Examples of detection ranking scores – manufacturing (AS13004:2017)
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.
Qualification
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.