RM13011 - Rework and Production Repair of Non-Conforming Products

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RM13011
Rework and Production Repair of
Non-Conforming Products
An AESQ Reference Manual

Supporting SAE AS13100™ Standard
Issued March 15, 2021
RM13011
Rework and Production Repair of
Non-Conforming Products
An AESQ Reference Manual

Supporting SAE AS13100™ Standard
AESQRM011202103
SAE Industry Technologies Consortia provides that: “This AESQ Reference Manual is published by the AESQ Strategy
Group/SAE ITC to advance the state of technical and engineering sciences. The use of this reference manual is entirely
voluntary and its suitability for any particular use is the sole responsibility of the user.”
Copyright © 2021 AESQ Strategy Group, a Program of SAE ITC. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by
any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of AESQ
Strategy Group/SAE ITC. For questions regarding licensing or to provide feedback, please contact info@aesq.sae-itc.org.
Aerospace Engine Supplier Quality (AESQ) Strategy

Group
The origins of the AESQ can be traced back to 2012. The Aerospace Industry was, and still is, facing many
challenges, including:
• Increasing demand for Aero Engines

• Customers expecting Zero Defects
• Increasing supplier / partner engine content
• Increasing global footprint
The Aero Engine manufacturers Rolls-Royce, Pratt & Whitney, GE Aviation and Snecma (now Safran Aircraft
Engines) began a collaboration project with the aim of driving rapid change throughout the aerospace engine
supply chain, improving supply chain performance to meet the challenges faced by the industry and the need
to improve the Quality Performance of the supply chain.
Suppliers to these Engine Manufacturers wanted to see greater harmonisation of requirements between the
companies. Each Engine Manufacturer had Supplier Requirements that were similar in intent but quite different
in terms of language and detail.
This collaboration was formalized as the SAE G-22 Aerospace Engine Supplier Quality (AESQ) Standards
Committee formed under SAE International in 2013 to develop, specify, maintain and promote quality standards
specific to the aerospace engine supply chain. The Engine Manufacturers were joined by six major Aero Engine
suppliers including GKN, Honeywell, Howmet Aerospace, IHI, MTU and PCC Structurals. This collaboration
would harmonise the aerospace engine OEM supplier requirements while also raising the bar for quality
performance.
Subsequently, the Aerospace Engine Supplier Quality (AESQ) Strategy Group, a program of the SAE Industry
Technologies Consortia (ITC), was formed in 2015 to pursue activities beyond standards writing including
training, deployment, supply chain communication and value-add programs, products and services impacting
the aerospace engine supply chain.
AESQ Vision
To establish and maintain a common set of Quality Requirements
that enable the
Global Aero Engine Supply Chain
to be
truly competitive through lean, capable processes
and a
culture of Continuous Improvement.
i
The SAE G-22 AESQ Standards Committee published six standards between 2013 and 2019:
• AS13000 Problem Solving Requirements for Suppliers (8D)

• AS13001 Delegated Product Release Verification Training Requirements (DPRV)
• AS13002 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans
• AS13003 Measurement Systems Analysis Requirements for the Aero Engine Supply Chain
• AS13004 Process Failure Mode & Effects Analysis and Control Plans
• AS13006 Process Control
In 2021 the AESQ replaced these standards, except for AS13001, with a single standard, AS13100.
The AESQ continue to look for further opportunities to improve quality and create standards that will add value
throughout the supply chain.
Suppliers to the Aero Engine Manufacturers can get involved through the regional supplier forums held each
year or via the AESQ website http://aesq.saeitc.org/.
ii
AESQ Reference Manuals

AESQ Reference Manuals can be found on the AESQ website at the following link:
https://aesq.sae-itc.com/content/aesq-documents
AESQ publishes several associated documents through the SAE G-22 AESQ Standards Committee supporting
deployment of AS13100. Their relationship with APQP and PPAP is shown in Figure 1.
Figure 1: AESQ Standards and Guidance Documents and the link to AS9145 APQP / PPAP
iii
RM13011 - Rework and Production Repair of Non-Conforming Products
Table of Contents
1. INTRODUCTION ..................................................................................................................................................... 2
2. NONCONFORMITY CONTROL PROCESS .................................................................................................................. 2
2.1 REVIEW AND DISPOSITION OF NONCONFORMING PRODUCTS .................................................................................... 2
2.2 CORRECTION BY REWORK ............................................................................................................................................. 3
2.3 CORRECTION BY PRODUCTION REPAIR ......................................................................................................................... 4
APPENDIX A: DEFINITIONS ............................................................................................................................................ 5
APPENDIX B: ACKNOWLEDGEMENTS ............................................................................................................................ 6
1
1. INTRODUCTION
This document supports AS13100 clause 8.7.1 and is intended to provide guidance on how to
comply with the requirement by providing more details with focus on rework and production repair
as correction of nonconforming products of Aerospace Engine Manufacturers. The guidance is
applicable for new part production only.
Note that the term Repair also includes remedial action taken on a previously conforming product to
restore it for use, for example as part of maintenance. This kind of repair on used products is
currently not covered in this guidance document since the control and documentation is handled as
a part of the instructions for continued airworthiness i.e. maintenance manuals.
Additional Guidance can be found in the IAQG Supply Chain Management Handbook Chapter 3.3.
Control of nonconforming outputs.
2. NONCONFORMITY CONTROL PROCESS
The requirements concerning control of nonconforming outputs are specified in AS9100. A short summary of
the main areas to be covered by the nonconformity control process is listed here.
The organization providing products is expected to have a nonconformity control process that is maintained as
documented information including the provisions for:
a) ensuring that nonconforming products are identified, segregated or controlled (if segregation is not
practical) to prevent their unintended use or delivery;
b) taking appropriate action based on the nature of the nonconformity and its effect on the conformity of
products. For correction of nonconforming products, see further details in Sections 2.2 and 2.3;
c) taking actions necessary to contain the effect of the nonconformity on other processes or products;
d) timely reporting of nonconformities affecting delivered products to the customer and to relevant interested
parties;
e) defining corrective actions for nonconforming products detected after delivery, as appropriate to their
impacts;
f) defining the responsibility and authority for the review and disposition of nonconforming products and the
process for approving persons making these decisions.
NOTE: The term “nonconforming product” includes nonconforming product generated internally, received from
an external provider, or identified by a customer.
2.1 REVIEW AND DISPOSITION OF NONCONFORMING PRODUCTS
When the organization providing products has discovered a nonconforming product an initial evaluation of the
nonconformity is performed.
The following are the dispositions that the appointed and approved person, within the organization providing
products, may make on nonconforming products:
Return, i.e. returning of the nonconforming product to the external provider from which it came.
Scrap, i.e. perform scrapping of the nonconforming product because it is obviously unfit for use and cannot be
economically reworked or repaired.
2
Correction by Rework, i.e. perform an action to eliminate a detected nonconformity on the product to make it
conform to the requirements. For correction by rework and use of standard repair procedure during rework,
see Section 2.2 for details.
Submit for further Disposition, i.e. if none of the above dispositions can be used, the nonconformity data
should be submitted for further investigation and disposition by a Design Authority and, when applicable by
the customer.
NOTE: The organization providing products will need to obtain acceptance and concession by the Design
Authority and, when applicable by the customer, in order to deliver nonconforming product.
To be able to deliver and use a nonconforming product that does not conform to the requirements a recorded
acceptance by concession is needed from the Design Authority, and when applicable from the customer if the
nonconformity results in a departure from the contract requirements.
Delegation of Design Authority to disposition nonconforming products is described in RM13008.
The following are the dispositions that the Design Authority, and when applicable the customer, are allowed to
make on nonconforming products:
Accept / Use-as-is, i.e. a disposition of a nonconforming product determined to be usable for its intended
purpose in its existing condition.
Correction by Production Repair, i.e. perform an action to eliminate a detected nonconformity on the
product to make it acceptable for the intended use. Production Repair can affect or change parts of the
nonconforming product. For correction by repair see Section 2.3 for details.
Reject, i.e. a disposition to reject the nonconforming product when an accept or production repair disposition
cannot be made. After the nonconforming product has been rejected, other actions may be considered by the
organization providing products such as developing a new production repair method and resubmit the
nonconformity data, or scrapping the nonconforming product.
Nonconformities on the product with the dispositions Accept / Use-as-is and Production Repair by concession
can be listed on the delivery documentation for the individual product, when required by the customer.
Nonconformities corrected by Rework is usually not shown on delivery documents, but are documented
together with the manufacturing records for the individual product.
2.2 CORRECTION BY REWORK
For the organization providing products to be able to use the disposition Correction by Rework the following is
expected:
Rework requires a procedure, using existing and approved manufacturing processes, applied to a
nonconformance that will completely eliminate it and result in a characteristic that conforms completely to the
product definition (i.e., drawings, specifications, models etc.).
The use of special processes not specified on the product definition to which the part is being produced or at
locations other than those specified on the product definition are not authorized as rework.
When “Fixed Process Control" or equivalent are specified on the product definition and any of the fixed
production process steps are affected by the proposed rework procedure specific requirements per customer
need to be considered.
Note that “optional production repair operations” already included in the manufacturing router for the
nonconforming product can be used as rework as long as they have been approved as a part of the
3
qualification of the product. For example an optional weld repair in the router that only will be performed when
needed based on results from previous inspection.
If any doubt exists that the proposed procedure to correct the nonconforming product will fulfil the definition of
Rework, the nonconformity data should instead be submitted for disposition to the Design Authority and, when
applicable to the customer.
A standard production repair procedure is a documented procedure for repair of a type of nonconformance
which has been demonstrated to be a technically adequate and cost effective method for repair when properly
applied to the product. Standard production repair procedures handled by concessions are approved by the
Design Authority and, when applicable by the customer, for recurrent use under defined conditions. Defined
conditions can include an expiration date or a finite limit on the number of application, or both.
After the initial approval of the standard production repair procedure, the organization providing products can
use it according to defined conditions without additional approval, if not otherwise required by the customer.
2.3 CORRECTION BY PRODUCTION REPAIR
When the organization providing products are submitting information concerning a nonconforming product to
the Design Authority and, when applicable to the customer, for disposition a proposed production repair
procedure can be included. More common is that first submitting data concerning a nonconforming product
and then creating the proposed production repair procedure after receiving information that the nonconforming
product not can be accepted as “Use-as-is”. The format for documenting the proposed production repair
procedure is normally specified by the Design Authority and, when applicable by the customer.
The proposed production repair procedure should contain, in detail, the exact method to be followed during
the production repair, i.e. restrictions or limitations for use of the production repair, related characteristics to
be re-inspected after completion of the production repair, tooling, special process inspection or test
requirements and any other requirements or considerations. Special consideration and instructions should be
given to assure that foreign objects or contaminants are not introduced into the product during the production
repair.
Nonconforming products should not be repaired by any method without prior approval of the production repair
procedure by the Design Authority and, when applicable by the customer. The level of approval of a proposed
production repair procedure can differ depending on the complexity of the production repair, but this is
normally handled internally by the Design Authority and, when applicable by the customer.
Authorization to perform a production repair procedure is limited to the provisions contained within the
approved production repair procedure. Activities within the production repair procedure are not to be
performed more than once, unless specifically provided for within the production repair procedure document.
When new nonconformities are a direct result of completion of the approved production repair, submittal for
disposition of the new nonconformity data should be performed.
When a nonconforming product is corrected it should be subject to re-verification to demonstrate conformity to

the requirements. The Design Authority and, when applicable the customer, reserves the right to request
evidence of production repair completion.
4
APPENDIX A: DEFINITIONS
Definitions
In addition to definitions per AS13100 the following apply.
Concession
Concession is a permission to use or release a product that does not conform to specified
requirements.
Design Authority
Design Authority is an authorized representative of the organization responsible for design, or
persons having delegated authority from the design organization, such as to accept nonconforming
products for use.
Fixed Processes
Fixed Processes are production process steps under engineering control that after initial approval
are fixed and not to be changed without engineering approval.
Product Definition
Product Definition is engineering requirements as documented within the drawing, Key
Characteristics, drawing notes, engineering specifications on the drawing, or referenced
engineering specifications, including Digital Product Definition, if applicable.
Production Repair
Production Repair is an action on a nonconforming product to make it acceptable for the intended
use. Production Repair can affect or change parts of the nonconforming product.
Note; Applicable for new part production only in this guidance document.
Rework
Rework is an action on a nonconforming product to make it conform to the requirements.
Scrap
Scrap is an action on a nonconforming product to preclude its originally intended use. For example
recycling, destruction.
Standard Production Repair Procedure
Standard production repair procedure is a documented technique approved for repetitive use for
repairing nonconformities that when properly applied, results in adequate and cost effective
methods for nonconformity resolution.
Note; Applicable for new part production only in this guidance document.
5
APPENDIX B: ACKNOWLEDGEMENTS
This reference manual represents the consensus of the members of the AESQ. The Team
members who developed this guidance and whose names appear below, wish to acknowledge the
many contributions made by individuals from their respective organizations.
Organization Representative
Rolls-Royce Ian Riggs – Team Leader
GKN Aerospace Lena Eckerbom Wendel – Team Co-Leader
GE Aviation Larry Bennett – Team Co-Leader
6
Change History
Revision Date Description of Change
March
Initial Release
2021
For more information or to provide feedback:
AESQ Strategy Group

400 Commonwealth Drive
Warrendale, PA 15096
Email: info@aesq.sae-itc.org

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Downloaded from SAE International by Souhail Chabat, Thursday, February 10, 2022

An AESQ Reference Manual

An AESQ Reference Manual

Aerospace Engine Supplier Quality (AESQ) Strategy

• Increasing demand for Aero Engines

• AS13000 Problem Solving Requirements for Suppliers (8D)

AESQ Reference Manuals