Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes

an example policy, procedure, a list of topics, forms and job descriptions

AS 9100 Rev C Aerospace Policies and Procedures

and Forms
The AS 9100 Quality Policies, Procedures, and Forms Manual will help you
create an AS 9100 Quality Management System (QMS) regardless of where
your company is located in the aerospace supply chain. The AS 9100 manual
addresses the issues of quality, safety, and reliability and explains in detail what
the AS 9100 standard is about. The manual will show you how to produce a
Quality Management Manual, and how to write AS 9100-based quality
procedures.
US$ 595.00 Includes five (5) modules:  Instant download
1. Introduction and Table of Contents  Available immediately
How to Order: 2. Guide to preparing a well written manual  (no shipping required)
Online: 3. Sample Manual covering common
www.bizmanualz.com requirements and practices
By Phone: 314-384-4183 4. 27 Policies and 47 corresponding forms
866-711-5837
Email: sales@bizmanualz.com
5. Complete Index

Document ID: Title: Print Date:

AS1150 MANUFACTURING
Revision #: Prepared By: Date Prepared:
0.0
Effective Date: Reviewed By: Date Reviewed:

Approved By: Date Approved:

Standard: SAE AS9100 (rev. C), clauses 7.5.1 and 7.5.2

Policy: The Company shall develop, implement, and maintain product realization processes
under controlled conditions which produce products that conform to requirements.

Purpose: To delineate the processes used to manufacture, inspect, and package product for
customer use.

Scope: This procedure applies to all personnel involved in the handling and production of
Company products and their components.

Responsibilities:

The Production Manager (Supervisor) is responsible for managing the Company's

production processes, ensuring that all personnel, materials, and equipment needed to
create and maintain the production schedule are available and able to function as
expected. The Production Manager is also responsible for ensuring that Production
personnel receive adequate training to perform their assigned duties; and that they
have complete, accurate and up to date production documentation.
 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

Manufacturing (production) personnel are responsible for producing the Company's end
product(s) in a manner that ensures quality and meets statutory/regulatory and
customer requirements.

Warehouse Personnel are responsible picking product for production.

Quality Control is responsible for monitoring and measuring all manufacturing (product
realization) processes, to ensure Company products conform to requirements.

Definitions: Benchmarking – Performance measurement tool used in conjunction with improvement

initiatives, it measures comparative operating performance of companies and identifies
best practices.

COTS – Commercial off-the-shelf; item, material, component, or system manufactured

commercially and tailored for a specific use, to reduce customer infrastructure and
costs.

Enterprise Resource Planning (ERP) – Information system or process that integrates

manufacturing and related applications for the entire enterprise (e.g., product planning,
parts purchasing, maintaining inventories, interacting with suppliers, providing
customer service, and tracking orders).

Flow diagram – Paths of movement of workers or materials, superimposed on a

graphical representation of the work area; also called a "process map".

Foreign object detection (FOD) – Discovering a foreign object (object that does not
belong) in a part, component, product, etc. Requirement of AS9100 – clause 7.5.1(i).
May be done at any stage of production, using various detection methods/tools (e.g., x-
ray, ultrasound).

Product realization – Act of bringing a product into existence; or, making a product.
Product realization is often synonymous with the terms "manufacturing" and
"production".

Procedure:

1.0 Production control

The Company shall control production processes in accordance with AS1140 CONTROL OF
PRODUCTION PROCESSES.

2.0 Kitting Work Orders

2.1 The Production Supervisor shall issue pick lists to the warehouse (storage) to kit the work orders.
The pick list indicates part numbers and locations for the materials to be issued to the work
order.
2.2 The assigned material handler shall pull the indicated items and record the quantity and location
pulled from on the pick list. The handler should mark the pulled package/container with the
work order number(s) to which it is being issued, especially if those items are being pulled for
more than one work order at the same time and location.
 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

2.3 If material packages (containers) must be broken to issue the correct quantity, the material handler
shall place the correct quantity into an appropriate container and clearly label the container
with the material name, quantity, purchase order number, and work order number.
 If the appropriate quantity of a material is not in the location indicated on the pick
list, the material handler shall attempt to find additional locations for the item on the
Company inventory system and, if found, note the quantity and actual location on the pick
list.
 If the item cannot be located in the plant, the material handler shall contact the
Production Supervisor immediately to determine if the kit should be held in storage until
complete and/or the work order should be rescheduled.
2.4 The material handler shall deliver the completed kit to Production with a copy of the completed pick
list.
2.5 Using the original pick list, Production shall enter all material issues from the actual locations on the
computer system. If location discrepancies were noted during kitting, Production shall notify
Material Control.
3.0 Production
3.1 The Production Supervisor shall assign the work order for the first operation on the Router (routing
sheet).
3.2 The Operator shall move parts, subassemblies, etc., issued on the work order to the work area.
3.3 The Operator shall follow the operating instructions on the Router. The Router shall indicate or
reference the appropriate production documentation.
 If the operating instructions call for operator inspection, inspection instructions must be
included and an operator checklist should be provided by QA, based on product
requirements. See AS1150-1 INSPECTION/ TESTING CHECKLIST for guidance.
 If the instructions call for Quality Assurance to conduct an inspection, the operator shall
forward the part(s) with inspection instructions to Quality Assurance (see section 3.0).
3.4 When the operation is complete, the operator shall complete the Router and forward the product
and work order packet to the next operation on the Router.
4.0 Inspection and Testing
4.1 Quality Assurance shall inspect Company products in accordance with requirements, to verify the
quality and conformity of parts and gauge the effectiveness of the design, development, and
production processes.
4.2 The QA Manager shall fill out AS1150-1 INSPECTION/TESTING CHECKLIST for the part to be
inspected, based on inspection requirements, key characteristics, etc. (see AS1050 CUSTOMER
AND PRODUCT REQUIREMENTS), and assign the inspection.
The QA Manager should include a detailed description/explanation of the inspection (see
section 4 of AS1150-1) and attach relevant inspection records, etc., as needed.

Depending on the nature, composition, and complexity of some items – and possibly due to
customer or other requirements – they will require inspection for the presence of foreign
 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

objects (Foreign Object Detection, or FOD). If FOD is required, this must be included on the
Inspection/Testing Checklist (see section 3, AS1150-1).

4.3 The inspector shall inspect the item (part, component, etc.) for conformance to all requirements
stated on the AS1150-1, checking the box in the "I" (inspected) column after each requirement.
If the inspector tests for conformance, the "T" (tested) column must be checked.
4.4 If the item fails to meet a requirement, the inspector shall indicate in the "Comments" section which
of the listed requirements was not met (referencing the requirement number on the form) and
include an explanation.
4.5 The inspector/tester shall sign and date the AS1150-1, indicating whether the part passed or failed
inspection/tests, and submit the checklist to the QA Manager.
4.6 The QA Manager shall review the checklist with Production, to determine whether to continue with
production.
4.7 If the product, part, component, etc., fails the inspection/test, the QA Manager shall dispose of the
item in accordance with AS1230 – CONTROL OF NONCONFORMING PRODUCT.
5.0 Packaging and Labeling
5.1 The packaging operator shall apply required labels to product packaging.
5.2 The operator shall record serial number sequence on the Router, if applicable.
5.3 The operator shall package finished products according to work instructions for the product.
5.4 The operator shall apply box labels to the packaged product in accordance with work
instructions and stage the product for release in the appropriate area.
5.5 If the product is a component to be used in a subsequent operation, the operator shall place the
product in an appropriate container and attach a tag, indicating the component name/ID and
work order number on the tag. Include a shop router, as needed.
6.0 Final VERIFICATION
QA or an individual designated by QA shall verify that the product, as packaged, conforms to
requirements

7.0 Final Release

7.1 Quality Assurance shall review all documentation in the work order packet to verify that it is
complete.
7.2 Quality Assurance shall verify that all inspections and testing have been performed and that the
product has passed all required inspections and tests. If reworked nonconforming parts,
materials, etc., have been included in the product to be released, Quality Assurance shall verify
that reworked product inspections have been performed and that the reworked product has
passed all inspections.
Effectiveness Criteria:

 Product completed by due date

 Consistency in meeting product due dates
 Reject and waste disposal rates
 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

 Elimination of quality/safety defects

 Amount of nonconforming product released to (found by) customer
 Reduction, elimination, or prevention of product recalls
 Performance rating from customer
Additional Resources:

A. Best Manufacturing Practices Center of Excellence (BMPCOE) – http://www.bmpcoe.org/

BMPCOE is a partnership among the Office of Naval Research's BMP Program, the Department
of Commerce, and the University of Maryland. Its objective is to empower defense and
commercial customers to operate at a higher level of efficiency and effectiveness.

B. Six Sigma Aerospace and Defense Benchmarking Association (6SADBA) –

http://www.sixsigmabenchmarking.com/6sadba.html
6SADBA is an association of aerospace and defense Six Sigma professionals within major
corporations or governmental agencies, dedicated to providing members with an opportunity to
identify, document, and establish best practices through benchmarking.

C. Massachusetts Institute of Technology Lean Aerospace Initiative (MIT LAI) –

http://lean.mit.edu/index.php
The Lean Aerospace Initiative is an evolving learning and research community that
brings together key aerospace stakeholders from industry, government, organized labor,
and academia. A consortium-guided research program, LAI is managed under the aegis
of the MIT Center for Technology, Policy and Industrial Development.
References:

A. Quality Procedures
 AS1000 DOCUMENT CONTROL
 AS1010 QUALITY RECORDS
 AS1140 CONTROL OF PRODUCTION PROCESSES
 AS1160 IDENTIFICATION AND TRACEABILITY
 AS1170 CUSTOMER PROPERTY
 AS1180 CONTROL OF MONITORING AND MEASURING DEVICES
Records/Forms:

 Production schedule
 Parts list(s)
 Pick list
 Shortage report
 Work orders and routers
 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

 Inspection sheets/reports
 Operating procedures; operator checklist(s)
 AS1150-1 INSPECTION/TESTING CHECKLIST
 Test results report
 Production measurement data
Revision History

Revision Date Description of changes Requested By

0.0 mm/dd/yy Initial Release

 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

AS1150-1 INSPECTION/TESTING CHECKLIST

Part Name Part ID

Fabricator/Assembler Fab./Assy. Date

Inspector Insp. Date

Tester Test Date

1. CUSTOMER REQUIREMENTS I T
a.  
b.  
c.  
d.  
2. REGULATORY REQUIREMENTS I T
a.  
b.  
c.  
d.  
3. OTHER REQUIREMENTS I T
a. Foreign Object Detection 
b. 
c. 
d. 
4. INSPECTION (attach narrative, spreadsheets, charts, etc., as needed)
a. Nature of inspection; technique(s) – describe
b. Inspection conditions
c. Observations/results
5. TESTING (attach information sheets, charts, etc., as needed)
a. Location
b. Restate/specify test requirements
c. Nature, type of testing (lab, simulator, in-flight, nondestructive, etc.); tools, techniques used
d. Test conditions
e. Observations/results
COMMENTS (attach additional sheets, if needed)

INSPECTION Pass / Fail Signature/Date

TESTING Pass / Fail Signature/Date

 Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions

AS 9100 Aerospace Rev C Policies and Procedures Manual:

27 Prewritten Policies and Procedures

1. Document Control 16. Manufacturing

2. Quality Records 17. Identification and Traceability
3. Management Responsibility 18. Customer Property
4. Job Descriptions 19. Control of Monitoring and Measuring Devices
5. Competence, Awareness, and 20. Customer Satisfaction
Training 21. Internal Quality Audits
6. Customer and Product Requirements 22. Monitoring and Measurement of
7. Sales Orders Processes
8. Customer Communication 23. Monitoring and Measurement of Product
9. Design and Development 24. Control of Nonconforming Material
10. Design Change 25. Data Analysis and Continual Improvement
11. Pre-Production Quality and Planning 26. Corrective Action
12. Supplier Evaluation 27. Preventive Action
13. Procurement
14. Receiving and Inspection
15. Control of Production/Service Processes
47 Corresponding Forms and Records
1. Document Request 22. Product Design Release
2. Document Control Database 23. Approved Supplier List
3. Quality Records List 24. Supplier Survey Form
4. Job Description 25. Supplier Performance Log
5. Employee Competence Matrix 26. Purchase Requisitions
6. Employee Development Plan 27. Purchase Order
7. Employee Group Training Record 28. Purchase Follow-Up
8. Individual Training Record 29. Receiving Log
9. Customer Requirements 30. First Article Inspection Report
Checklist 31. Receiving/Inspection Report
10. Customer Order 32. Inspection/Testing Checklist
11. Customer Communication Plan 33. Material Return Notice
12. Customer Service Log 34. Calibration Record
13. Customer Service Contact Form 35. Calibration Database
14. Request for Engineering Action 36. Post-Sale Satisfaction Report
15. Requirements Definition 37. Customer Satisfaction Survey
16. Product Brief 38. Customer Service Log
17. Design Review Checklist 39. Audit Schedule
18. Design Completion Checklist for 40. Audit Plan
Electromechanical Devices 41. Quality Audit Checklist
19. Design Completion Checklist for Non- 42. Final Audit Report
Electromechanical Devices 43. Nonconformance Report
20. Product Test 44. Returned Goods Authorization
21. Engineering Change Notice 45. Corrective Action Request
46. Corrective Action Log