SAE AS 13002-2015 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans.pdf

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4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS13002 AEROSPACE STANDARD AS13002 Issued 2015-03 Requirements for Developing and

5、 Qualifying Alternate Inspection Frequency Plans RATIONALE Aero-engine companies currently have their own requirements for Inspection Frequency which are very similar. A single standard would be more efficient for suppliers. The following standard is a consolidation of these methods to allow for a s

6、ingular standard for Developing Inspection plans other than 100% inspection of all features. 1. SCOPE This document covers the process to be applied to design characteristics (as defined in AS9102), parts or inspection processes as defined by the purchaser. Design characteristics not included within

7、 the scope include electronic, electromechanical or mechanical systems where alternative means of acceptance are approved such as through acceptance test procedures (ATPs). This document does not define processes for identifying or communicating the classification of the parts or design characterist

8、ics. This document does not define the procedure to qualify a supplier to undertake these requirements. It is expected that each purchaser will have a procedure to manage the flow-down of these requirements. This document applies to suppliers that demonstrate adequate proficiency in applicable proce

9、ss control methods as determined by the purchaser. 1.1 Purpose The purpose of this document is to provide common requirements for developing and qualifying an alternate inspection frequency plan where characteristics are not inspected 100% of the time. 2. REFERENCE DOCUMENTS The following documents

10、provide useful guidance when implementing the requirements of this standard: 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AS9100 Quality Management Syste

11、ms - Requirements for Aviation, Space and Defense Organizations AS9102 Aerospace First Article Inspection Requirement AS9103 Aerospace Series - Quality Management Systems - Variation Management of Key Characteristics AS13000 Problem Solving Requirements for Suppliers AS13003 Requirements for MSA the

12、 act of minimizing variation of a process PROCESS CHARACTERISTIC: The specific process inputs that have an effect on design characteristics. PROCESS MONITORING: Measuring and recording process inputs and/or outputs against process operating limits to verify that process stability has not significant

13、ly changed. PURCHASER: The customer issuing the purchase order for the part subject to the alternate inspection frequency plan. REDUCED INSPECTION: A type of alternate frequency inspection plan where less than 100% inspection of selected characteristics within a group of characteristics on a single

14、part, however, all parts are inspected. The group of characteristics are created by the same process and the conformity of un-inspected characteristics within the group is inferred by the inspected characteristics within the same group. SAMPLE INSPECTION: A type of alternate frequency inspection pla

15、n. The inspection of selected characteristics on sampled parts from which the conformity of the same characteristics on other parts is inferred. SPECIFICATION LIMITS: The acceptable limits which a design characteristic can vary within (e.g., the tolerance on a drawing/print). SUPPLIER: The organizat

16、ion/vendor receiving the purchase order and responsible for the manufacture and inspection of the part(s) subject to these requirements. 3. TRAINING 3.1 Suppliers applying these requirements are assumed to be competent in quality management methods and statistical techniques such as Statistical Proc

17、ess Control and Measurement Systems Analysis. 3.2 The supplier shall determine and document specific training requirements relevant to their organization appropriate to operate this process. Minimum elements of this training are subject to purchaser approval. 4. OVERVIEW OF INSPECTION FREQUENCY REQU

18、IREMENTS This standard defines the requirements to implement an alternate inspection frequency plan. The steps to implement these requirements are as follows: SAE INTERNATIONAL AS13002 Page 5 of 21 Figure 1 - Process flow Start, The launch point at which a number of pre-requisites are expected to be

19、 in place. Typically the supplier will enter into a discussion with the purchaser at this stage to agree to a broad approach. Define Characteristics and Controls, The supplier determines the characteristics within scope of the alternate inspection frequency plan and the appropriate control types. Pr

20、epare Data Pack, The activity a supplier undertakes to gather the data to substantiate the proposed alternate inspection frequency plan. Purchaser Evaluation and Approval, The evaluation by the purchaser of the proposed alternate inspection frequency plan and its subsequent approval or rejection. Ex

21、ecute Plan and Monitor, Once a plan is approved the supplier will begin to operate the plan and monitor as required. Reaction Plan, Following identification of an issue a reaction plan shall be enacted to contain the issue and return to the alternate inspection frequency plan. 5. INSPECTION FREQUENC

22、Y PROCESS 5.1 Prerequisites 5.1.1 The supplier shall have a documented process within its own quality system to control inspection which meets the requirements set forth by the purchaser. The process shall be fully implemented and subject to audit by the supplier and the purchaser. 5.1.2 The documen

23、ted inspection frequency process shall describe the training requirements for practitioners. 5.1.3 A full first article inspection for the part(s) shall be in place in accordance with the purchaser requirements. Prepare Data PackPurchaser Evaluation alternatively other forms (electronic or paper) ma

24、y be utilized provided they meet the same intent and are agreed between the supplier and purchaser. SAE INTERNATIONAL AS13002 Page 9 of 21 http:/www.sae.org/servlets/works/committeeHome.do?comtID=TEAG22 PlanType:DC no.DC NameProcessIDOperationno.DateNumberofpartsmeasuredStableY/NPpPpkTypeControlcard

25、InspectionFrequencyProcess CapabilityReviewNameNotesDateOngoing MonitoringMethodsApprovalfromCustomerC ont r o lli ng C h ar DESIGNCHARACTERISTIC(S)ProcessProcessCapabilityStudyMeasurmentMeansD C C l ass i f i c at i o nSAE INTERNATIONAL AS13002 Page 10 of 21 7. APPENDIX - CONTROL TYPES The followin

26、g tables describe the requirements of five different alternate inspection frequency plans. 7.1 Statistical Process Control 7.1.1 Requirements for Sampling of Variables Data Description Application Data Pack Contents On-Going Monitoring The quality of the product is assured by process monitoring a ca

27、pable process at a defined frequency against statistically defined operating limits. Appropriate: This method may be employed when it can be shown that the output from a process is stable, the capability is sufficient and the risk of non-conforming product is minimal. NOTE: The classification of cha

28、racteristics may influence the sampling plan Not Appropriate: When the process is a manual method and the operator has a high-degree of influence over the process capability. A technical description of the process to demonstrate how it operates and how it is controlled. Non-conformance history for t

29、he current method of manufacture for the part. Analysis based on data collected from a minimum of 25 measurements that fully represent the process behavior taking into account for example multiple batches, operators, shifts, setups. A minimum of three setups should be represented A visual assessment

30、 of the behavior of the process to demonstrate whether specific process behavior is evident (i.e., batching) and needs to be considered when defining the sampling plan. An appropriate control chart to demonstrate statistical process control. A normality assessment of the process (see Statistical Pro

31、cess Control (SPC) - Automotive Industry Action Group). If the process is deemed non-normal then the purchaser shall be consulted. Distribution fitting prior to capability analysis may be required A relevant capability analysis assessed against minimum acceptable criteria Ppk 1.33 for major characte

32、ristics or Ppk 1.0 for minor characteristics. A proposed operating limit for the characteristics to be monitored If the process is continuous (i.e., no batch to batch variation or process drift over time) then apply standard 3 sigma control limits based on control chart or process standard deviation

33、. If batch to batch variation is evident then limits may be set using alternative methods and rationale for the limits and alternate inspection frequency plan contained in the technical submission Operating limits shall never be outside the specification for the characteristic. The supplier shall mo

34、nitor at the frequency and to the operating limit defined in the control plan. Any failure against limits shall require full inspection of the batch and appropriate problem investigation. Following problem resolution an agreed number of consecutive parts shall be inspected at 100% level to validate

35、the effectiveness of the solution prior to resuming sample inspection. SAE INTERNATIONAL AS13002 Page 11 of 21 A proposed inspection frequency. The inspection frequency shall be determined from the inspection frequency tables contained within this standard. Any proposal outside the guidelines of the

36、 table shall require explicit purchaser approval (technical justification shall be required) The suppliers on-going process and product monitoring and reaction plan shall be submitted in the form of a process control plan for approval by the purchaser. NOTE: Process based studies may be acceptable t

37、o allow qualification by similarity to completed, e.g., similar parts, geometries, tolerances, design characteristics (supplier shall liaise with their purchaser to confirm suitability). 7.1.2 The supplier shall ensure sampling rates are at or greater than the minimum rates defined within Table 2 an

38、d 3, and shall only operate outside these rates with purchaser approval. This will depend on level of risk and process control. NOTE: For continuous process (single piece flow) where no batching exists, the sampling rate may be based on a frequency of product basis (1 in X or X%). The frequency perm

39、issible will depend on quality performance, process controls and operational risk and shall be approved by the purchaser. 7.1.3 When sampling from large batches of components other methods may be permissible such as monitoring of the average, standard deviation and range. These methods are not discu

40、ssed in this standard and shall require a separate technical justification 7.1.4 Major Characteristics - Sampling Table Table 2 - Major characteristics sampling table NOTE: Batch sizes above 2000, sample size to be agreed upon with the purchaser. MajorPpk up to 10 11 to 20 21 to 30 31 to 45 46 to 60

41、 61 to 90 91 to 120 121 to 1502 and above 222345661.66 to 1.99 34556912151.33 to 1.65 5 1010111218 430less than 1.33 ALL ALL ALL ALL ALL ALL ALL ALLMajorPpk 151 to 200 201 to 250 251 to 300 301 to 500 501 to 750 751 to 1000 1001 to 20002 and above 8 1012203040501.66 to 1.99 20 20 20 25 38 40 501.33

42、to 1.65 40 50 50 50 50 50 80less than 1.33 ALL ALL ALL ALL ALL ALL ALLBatch SizeBatch SizeSAE INTERNATIONAL AS13002 Page 12 of 21 7.1.5 Minor Features - Sampling Table Table 3 - Minor characteristics sampling table NOTE: Batch sizes above 2000, sample size to be agreed upon with the purchaser. 7.1.6

43、 Reduced Inspection of Variables Description Application Data Pack Contents On-Going Monitoring The conformance of a group of identical characteristics is assured through the process monitoring of a reduced set of controlling characteristics from the group. Every component is inspected but not every

44、 characteristic. Appropriate: This method may be employed when it can be shown that a sub-set of product characteristics has a direct relationship to the conformance of the whole group, e.g., features created within the same operation such as a group of holes, drilled together where the first and la

45、st hole are used as controlling characteristics for the rest of the holes. NOTE: The classification of characteristics may influence the sampling plan A technical description of the process to demonstrate how it operates and how it is controlled. Identical characteristics shall be identified and rat

46、ionale for their grouping defined. Non-conformance history for the current method of manufacture for the part. Data gathered from all features within the identical feature group over a number of components as agreed with the purchaser. A visual assessment of the behavior of the process to demonstrat

47、e within and between part variation. An appropriate control chart to demonstrate statistical process control relevant to the submission. A normality assessment of the process. If the process is deemed non-normal then the purchaser shall be consulted. Distribution fitting prior to capability analysis

48、 may be required A correlation study or relevant capability analysis/product study assessed against minimum acceptable criteria as agreed with the purchaser. Within feature group variation shall be assessed. The supplier shall monitor at the frequency and to the operating limit defined in the contro

49、l plan. Any failure against operating limits shall require full inspection of the characteristic group. Any non-conformance shall require an appropriate problem investigation. Following problem resolution a level of full product inspection shall take place to validate the corrective action prior to resuming the alternate inspection frequency plan. This may involve inspecting multiple parts. MinorPpk up to 10 11 to 20 21 to 30 31 to 45 4