Jig and Tool Instruction 

Quality Assurance
Acceptance, Testing,
Release and Inspection 81-T-06-0201
Marks of Special Tooling Issue: 02/05
Page 1 of 8

CONTENT

1 PURPOSE 2

2 SCOPE AND APPLICATION 2

3 RESPONSIBILITY 2

4 TERMS 2

5 ACCEPTANCE, TESTING, RELEASE AND INSPECTION MARKS OF 2

SPECIAL TOOLING 2

6 APPLICABLE STANDARDS AND SPECIFICATIONS 8

Appendix 1: List of open points (LoP) (example)

Appendix 2: List of open points (LoP) (empty sheet for completion)

Prepared by Agreed with Revised by

Specialist team: Plant representatives: HB 81 accountable:

Gröne TRLQ7 Thomas TSZ3 Schnülle TRVV4

Hoffmann TRBQ12 Dietrich TRVV1
Panczak TRLQ72 Drieling TRVV4
Plantör TRVV201 Öhenbrink TRBM42
Saule BCLE32
Schnier TRNZ23
Techert TRZ48

Released: CoC Jigs&Tools

signed: Votteler

All instructions are originally compiled, checked and approved in the German
language.
In case of discrepancies resulting from possible translation errors or misinterpretation
of the English text, the German version shall apply.

Former issue: 08/00

Limitation of use: CoC Jigs&Tools Suppliers Observe protection notice per DIN ISO 16016

 
 
  Page 2 81-T-06-0201 (02/05)

1 PURPOSE

It is the purpose of this instruction to define quality assurance measures including

responsibility for new, duplicated, changed and repaired special tooling and their control
systems, NC programs and special test equipment.
The definitions applying to the scheduled inspection are described in Jig and Tool Instruction
81-T-06-0301.

2 SCOPE AND APPLICATION

This instruction is valid for Airbus Deutschland GmbH.

3 RESPONSIBILITY

Responsibility for compliance with this instruction is as follows:

- The CoC Jigs&Tools / organizational unit manager is responsible for the observance
and surveillance of the performance of in-process test organization in compliance with
this instruction.
- The quality assurance manager is responsible for the observance and surveillance of
the procedure documented herein.

4 TERMS

OP = operation
Type sample = qualification sample
DP = data processing
First article = first unit manufactured under series conditions
ST = special tooling
QA = quality assurance
QAI = quality assurance instruction
IGD = incoming goods department
LoP = list of open points

5 ACCEPTANCE, TESTING, RELEASE AND INSPECTION MARKS OF

SPECIAL TOOLING

5.1 Introduction

It is basically assumed for ST that defect prevention takes precedence over defect detection
(with subsequent correction of defects).
The present QAI deals with the compliance with general or product-related, quality
requirements.
Defects are detected at an early stage, i.e. prior to the official release of ST, and are corrected
by measures immediately taken.
A manufacturing order for ST is considered settled only after completion of the testing of ST
with a positive result.

 
 
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5.2 Preventive Measures

The QA department is to be consulted during the planning and design of highly complex
and/or extremely accurate ST as well as for any ST with a high quality risk.
In detail, the following criteria are affected:

- ST and gauge concept

- consistency of reference procedures with special consideration of
interchangeability criteria
- feasibility (referred to accuracy)
- tolerances
- measurement techniques/measuring methods/measuring system
- documentation of actual dimensions (record sheets)
- selection of manufacturers

Additional are to be used the procedures according to QVA-Z06-04-00.

5.3 Release Procedure

5.3.1 Inspection and Documentation

5.3.1.1 Inspection

Geometry and, as far as possible, function should generally be inspected on new, duplicated
and, if geometry and/or function are affected, also on changed and repaired ST.
Depending on the type of ST, the inspections are based on:

- ST-drawings
- component drawings
- manufacturing orders for ST
- inspection drawing for ST/table of dimensions
- ST inspection plan
- interchangeability drawing (ICY drawing)
- reference gauges for ST
- work specification
- requirement specification/contract specification
- first article inspection
- 3D-surfaces

5.3.1.2 Documentation of Actual Dimensions

The actual dimensions are to be documented. The type of documentation depends on the
inspection devices used.

In detail, the following types of documentation can be used:

- print-outs of computer-aided inspection devices

- data storage on DP storage media
- entries on record sheets
- entries on ST drawings
- entries on inspection drawings

 
 
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5.3.1.3 Inspection of ST without Subsequent Testing

No tests are required for certain types of ST. This concerns relatively simple ST for which an
accurate statement by ST Inspection according to a ST or component drawing will be
sufficient.
If the QA of the user of ST decides that no tests are required for certain ST, then the relevant
OP in the ST manufacturing order are to be provided with the reference "without testing" and
an inspection mark by the ST planning department. The ST manufacturing order is to be
forwarded to ST Control to give notice of the availability of ST (assignment of status). The
inspection marking is to be accomplished in accordance with 5.7.1.2.

5.3.2 Testing

5.3.2.1 Introduction
Testing of ST is to be performed under real operating conditions at the user of ST. Testing is
controlled via the manufacturing order for ST which must always contain the following
operations:
- ST inspection (to be performed by manufacturer of ST)
- first article testing and functional testing of ST together with the component order (to
be performed by user of ST)
Testing is performed almost exclusively in connection with the manufacture of the first series
components. In exceptional cases, a type sample may be required prior to actual series
production; its need is controlled via separate testing orders for ST.
Prior to application of one of the release procedures described below, the need for inspection
is to be determined by the QA of the user of ST. QA guidelines (decision criteria) prepared
within the company can be very useful for the assessment of the need for inspection.
For NC programs, the corresponding release procedures of the manufacturing plant are to be
applied.

5.3.2.2 Testing Criteria

ST is tested in order to demonstrate that the quality requirements for the components and the
requirements for proper functioning of ST are met. The function has to include the following:
- design
- accessibility
- handling
- risk of confusion (wrong installation of component possible)
- risk of accidents
- economy

5.3.2.3 Test Performance for ST

Subsequent to the manufacture and inspection of ST, it is to be passed on to the component
production or testing department by Production Control, together with the component
manufacturing order.
Here the following is carried out:
- manufacture of the first series components or, in exceptional cases, the type
sample;
- assessment of functional criteria according to section 5.3.2.2 by the production
or testing department;

- assessment of the quality of the components by the QA of the user of ST.

 
 
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ST is released exclusively by the user of ST, subsequent to testing.

On principle, any completed ST manufacturing order is to be passed on to archiving division.
Testing of NC programs is performed within the first article inspection.
ST for assembly may be tested only with detail parts/units manufactured with released ST.
Testing comprises the assembly of detail parts/units in ST to be tested and subsequent
installation of the assembled unit into next-following ST for assembly. The inspection marking
is to be accomplished in accordance with 5.7.1.2.

5.3.2.4 Inspection of ST with Subsequent Testing

For a number of ST, only inspection and tests can show that components of the required
quality can be manufactured with this ST.
The inspection is performed according to section 5.3.1 and the subsequent testing of ST is
performed according to section 5.3.2. The inspection marking is to be accomplished in
accordance with 5.7.1.2.

5.4 Non-conformances

If ST is rejected during its first use, the procedure "Q-Declaration" in SAP is to be applied in all
cases. Additional with large projects can be used further procedures as e.g. LoP-lists.
Determined defects of the ST are in structured form to eliminate. Therefore it is expedient to
establish project teams for analysing the mistakes and dissolving the problems.
Subsequent to correction of the non-conformance, the procedures defined in the present QAI
are reapplied.

5.5 Changes

As far as QA measures for ST are concerned, the present ST instruction is to be reapplied for
changes.

5.6 ST from External Manufacture

5.6.1 General

The OP "ST inspection" with documentation of inspection attributes (as per section 5.3.1.2)
can be performed:

- by the manufacturer (the ordering plant must countersign the test record and
make a spot test, if necessary)

- by the ordering plant at the manufacturers

- by QA of the user of ST subsequent to receipt of ST at the user plant.

The respective procedure used is to be defined in the ordering papers by ST Planning of the
ordering plant in agreement with ST user.

5.6.2 Incoming Inspection, Testing and Release at the User Plant

 
 
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Subsequent to receipt of ST including documents, it is inspected by the IGD for:

- identity
- completeness (ST + documentation)
- transport damage

The IGD arranges for forwarding of

- ST to the user. If a ST manufacturing order including the OPs defined in section

5.3.2.1 does not yet exist for completely finished ST, this order must be
prepared by ST Planning and passed on to ST user.

Further procedure is according to the definitions as of section 5.3.

5.7 Inspection Marks

5.7.1 General

In the case of a positive result, ST inspections and final inspections performed are
documented by means of horizontal inspection marks on the ST identification plates.

If inspections are to be repeated due to changes, the performance is to be documented on

the ST modification plate by means of a horizontal inspection mark and a change index. If
there is not enough space provided for the inspection mark to be applied in the block of the
ST modification plate, it is to be removed and replaced by a new ST modification plate with
inspection mark and change index.

The old inspection mark of ST without identification plate is to be removed mechanically and
the changed ST reidentified by inspection mark and change index.
For inspection marks of NC programs the corresponding guidelines of the manufacturing plant
are to be applied.

5.7.1.1 Explanation of Inspection Marks

- First inspection mark = ST inspection

- Second inspection mark = testing of ST

 
 
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5.7.1.2 Inspection Marking Procedure

In the case of a positive result, ST manufacturer documents completion of the OP "ST

inspection" by means of a horizontal inspection mark on the ST identification plate.
SA without testing receive as release a second horizontal inspection mark by ST
manufacturer.

Figure 1: ST inspection without testing performed

ST with testing and with a positive result must be provided by the SA manufacturer with a first
horizontal and by the QA of the ST user with a second vertical inspection mark on the ST
identification plate after positive testing.

Figure 2: Inspection and testing of ST performed

5.7.1.3 Inspection Marks for ST from External Manufacture

If ST has been inspected by the manufacturer, the QA of the user of ST provides the
ST identification plate (analogous to Figure 2) with a first horizontal and a second vertical
inspection mark subsequent to positive completion of first article testing and functional testing
of ST in the plant using ST.

At ST without testing the inspection marks must be performed analogous to Figure 1.

 
 
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6 APPLICABLE STANDARDS AND SPECIFICATIONS

81-T-02-4101 Marking of Special Tooling

81-T-06-1001 Periodic Inspection Drawing

81-T-07-0101 CE Marking of Special Tooling

QVA-Z06-04-00 Measures Concerning Planning and Procurement of

Manufacturing and Test Equipment

QVA-Z08-06-00 Implementation and Execution of CE Conformity Marking

at the EADS Airbus GmbH

QVA-Z09-16-00 First Article Inspection

QVA-Z16-03-00 Recording and Evaluation of Discrepancies