Counterfeit parts, Conflict minerals and Product safety

This 2-day course covers in detail everything that is needed to develop, document and implement Rev D 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 re-certification and routine surveillance audits - so be fully prepared!. The course is highly interactive and includes many team exercises, scenarios and quizzes.

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



Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments on each training day

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.

Details/quote

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.

Counterfeit parts and Product safety are mandatory requirements of AS9100:2016 Rev D - and 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.

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.


Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

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