SUPPLIER QUALITY - CTRM SQR 001 Rev.C.pdfAS9145 Requirements for Advanced Product Quality Planning...
Transcript of SUPPLIER QUALITY - CTRM SQR 001 Rev.C.pdfAS9145 Requirements for Advanced Product Quality Planning...
SUPPLIER
Effective Date
1st Jan 2019
REQUIREMENTS
QUALITY
1
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 1 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
WARNING
copyCTRM AC All Rights reserved Confidential and proprietary document
This document and all information contained herein is the sole property of CTRM AC
No intellectual property rights are granted by the delivery of this document or the
disclosure of its content This document shall not be reproduced or disclosed to a third
party without the express written of CTRM AC This document and its content shall not
be used for any purpose other than that for which it is supplied This document also
available in our website as below
httpswwwctrmcommy
Zahirah Shaik Dawood Head of Department
Supplier Quality Assurance
Hisham Marjohan Head of Division
Supplier Management
Approval
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 2 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
Revision Date Description of Changes
NC 13- August 15 Initial Release
A 17- October 16 Completely re-written and re-formatted ndash All paragraph
B 06- Nov ndash 2017
Add 13 ndash SQR 001 availability at CTRM website
Add 30 ndash Communication Interaction
Add 124 ndash NADCAP M amp I for CMS
Add 170 ndash Obsolescence Notification
Add 180 ndash Calibration Services Requirements
Add 202 amp 203 ndash Counterfeit Part
Add 213 ndash Delegation Verification Activity
Add 214 ndash Design Responsible Supplier
Add 223 ndash Metallic Raw Material Validation
Add 321 till 325 ndash Training and Staffs Competencies
Add 327 ndash Vision Requirements
Add 350 ndash Foreign Object Damage (FOD)
Add 451 amp 452 ndash Escalation Process
Add 462 ndash Verification And Validation Activities
Add 480 ndash Critical Item And Key Characteristic Control
C 01-Jan - 2019
New Clause
Add 30 ndash Specific Requirements ndash By CTRM ACrsquos Customer Add 180 ndash Distributor Requirement
Add 190 ndash Manufacturer of Standard Parts
Add 230 ndash Delegation of Product Verification
Add 250 ndash Test Specimens Requirement
Add 260 ndash Validation and Control of Special Processes
Add 270 ndash IM amp TE
Add 460 ndash Add Form 542
Add 470 ndash Add 473 ndash 476
Add 500 ndash Requirements for APQP
Add 520 ndash NADCAP Certification
Add 530 ndash Contingency Plans
Add 540 ndash Supplier Performance Rating
REVISION HISTORY
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 3 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
ANSINCSL Z5403 Requirements for Calibration of Measuring and Test Equipment
AS 6174 Counterfeit Materiel Assuring Acquisition of Authentic and Conforming Materiel
AS13000 Problem Solving Requirements for Suppliers
AS13002 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans
AS9015 Supplier Self Verification Process Delegation Programs
AS9100 Quality Management System Requirements (Aerospace)
AS9102 Aerospace First Article Inspection Requirement
AS9103 Variation Management of Key Characteristics
AS9117 Delegated Product Release Verification
AS9120 Quality Management System Requirements (Stockiest Distributor)
AS9130 Quality System Record Retention
AS9145 Requirements for Advanced Product Quality Planning and Production Part
Approval Process
AS9146 Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation
Space and Defense Organizations
CAP-06-014 Digital Product Definition (DPD) for Suppliers
IAQG International Aerospace Quality Group
ILAC International Laboratory Accreditation Cooperation
ISO 10005 Quality Management Systems - Guideline for Quality Plans
ISO 10012 Measurement management systems Requirements for measurement processes
and measuring equipment
ISO 14001 Environmental Management Standards
ISO 17025 Quality Management System Requirements (Testing and Calibration Lab)
ISO 9001 Quality Management System Requirements
OASIS Online Aerospace Supplier Information System
httpwwwsaeorgPORTAL_CODE=IAQG
OHSAS18001 Occupational Health and Safety System
PRI AC 7004 NADCAP Audit Criteria for Inspection and Test Quality system
REACH Registration Evaluation Authorization and Restriction of Chemicals
RoHS Restriction of Hazardous Substances Directive
SQR 002 Supplier Quality Requirement - Delegated Quality Representative Program
(DQRP)
Form 004 Good Discrepancy Report (GDR)
Form 045 Engineering Query Notes (EQN)
Form 138 Stop Note
Form 191 Change Note (CN)
Form 297 Service Discrepancy Report (SDR)
Form 329 Supplier Corrective Action Report (SCAR)
Form 479 Supplier Request for Change Form
Form 542 Supplier Notice of Escape (NoE)
Compliance Matrix Form
Supplier Acknowledgement
REFERENCE IN SQR
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 1 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
WARNING
copyCTRM AC All Rights reserved Confidential and proprietary document
This document and all information contained herein is the sole property of CTRM AC
No intellectual property rights are granted by the delivery of this document or the
disclosure of its content This document shall not be reproduced or disclosed to a third
party without the express written of CTRM AC This document and its content shall not
be used for any purpose other than that for which it is supplied This document also
available in our website as below
httpswwwctrmcommy
Zahirah Shaik Dawood Head of Department
Supplier Quality Assurance
Hisham Marjohan Head of Division
Supplier Management
Approval
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 2 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
Revision Date Description of Changes
NC 13- August 15 Initial Release
A 17- October 16 Completely re-written and re-formatted ndash All paragraph
B 06- Nov ndash 2017
Add 13 ndash SQR 001 availability at CTRM website
Add 30 ndash Communication Interaction
Add 124 ndash NADCAP M amp I for CMS
Add 170 ndash Obsolescence Notification
Add 180 ndash Calibration Services Requirements
Add 202 amp 203 ndash Counterfeit Part
Add 213 ndash Delegation Verification Activity
Add 214 ndash Design Responsible Supplier
Add 223 ndash Metallic Raw Material Validation
Add 321 till 325 ndash Training and Staffs Competencies
Add 327 ndash Vision Requirements
Add 350 ndash Foreign Object Damage (FOD)
Add 451 amp 452 ndash Escalation Process
Add 462 ndash Verification And Validation Activities
Add 480 ndash Critical Item And Key Characteristic Control
C 01-Jan - 2019
New Clause
Add 30 ndash Specific Requirements ndash By CTRM ACrsquos Customer Add 180 ndash Distributor Requirement
Add 190 ndash Manufacturer of Standard Parts
Add 230 ndash Delegation of Product Verification
Add 250 ndash Test Specimens Requirement
Add 260 ndash Validation and Control of Special Processes
Add 270 ndash IM amp TE
Add 460 ndash Add Form 542
Add 470 ndash Add 473 ndash 476
Add 500 ndash Requirements for APQP
Add 520 ndash NADCAP Certification
Add 530 ndash Contingency Plans
Add 540 ndash Supplier Performance Rating
REVISION HISTORY
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 3 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
ANSINCSL Z5403 Requirements for Calibration of Measuring and Test Equipment
AS 6174 Counterfeit Materiel Assuring Acquisition of Authentic and Conforming Materiel
AS13000 Problem Solving Requirements for Suppliers
AS13002 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans
AS9015 Supplier Self Verification Process Delegation Programs
AS9100 Quality Management System Requirements (Aerospace)
AS9102 Aerospace First Article Inspection Requirement
AS9103 Variation Management of Key Characteristics
AS9117 Delegated Product Release Verification
AS9120 Quality Management System Requirements (Stockiest Distributor)
AS9130 Quality System Record Retention
AS9145 Requirements for Advanced Product Quality Planning and Production Part
Approval Process
AS9146 Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation
Space and Defense Organizations
CAP-06-014 Digital Product Definition (DPD) for Suppliers
IAQG International Aerospace Quality Group
ILAC International Laboratory Accreditation Cooperation
ISO 10005 Quality Management Systems - Guideline for Quality Plans
ISO 10012 Measurement management systems Requirements for measurement processes
and measuring equipment
ISO 14001 Environmental Management Standards
ISO 17025 Quality Management System Requirements (Testing and Calibration Lab)
ISO 9001 Quality Management System Requirements
OASIS Online Aerospace Supplier Information System
httpwwwsaeorgPORTAL_CODE=IAQG
OHSAS18001 Occupational Health and Safety System
PRI AC 7004 NADCAP Audit Criteria for Inspection and Test Quality system
REACH Registration Evaluation Authorization and Restriction of Chemicals
RoHS Restriction of Hazardous Substances Directive
SQR 002 Supplier Quality Requirement - Delegated Quality Representative Program
(DQRP)
Form 004 Good Discrepancy Report (GDR)
Form 045 Engineering Query Notes (EQN)
Form 138 Stop Note
Form 191 Change Note (CN)
Form 297 Service Discrepancy Report (SDR)
Form 329 Supplier Corrective Action Report (SCAR)
Form 479 Supplier Request for Change Form
Form 542 Supplier Notice of Escape (NoE)
Compliance Matrix Form
Supplier Acknowledgement
REFERENCE IN SQR
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 2 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
Revision Date Description of Changes
NC 13- August 15 Initial Release
A 17- October 16 Completely re-written and re-formatted ndash All paragraph
B 06- Nov ndash 2017
Add 13 ndash SQR 001 availability at CTRM website
Add 30 ndash Communication Interaction
Add 124 ndash NADCAP M amp I for CMS
Add 170 ndash Obsolescence Notification
Add 180 ndash Calibration Services Requirements
Add 202 amp 203 ndash Counterfeit Part
Add 213 ndash Delegation Verification Activity
Add 214 ndash Design Responsible Supplier
Add 223 ndash Metallic Raw Material Validation
Add 321 till 325 ndash Training and Staffs Competencies
Add 327 ndash Vision Requirements
Add 350 ndash Foreign Object Damage (FOD)
Add 451 amp 452 ndash Escalation Process
Add 462 ndash Verification And Validation Activities
Add 480 ndash Critical Item And Key Characteristic Control
C 01-Jan - 2019
New Clause
Add 30 ndash Specific Requirements ndash By CTRM ACrsquos Customer Add 180 ndash Distributor Requirement
Add 190 ndash Manufacturer of Standard Parts
Add 230 ndash Delegation of Product Verification
Add 250 ndash Test Specimens Requirement
Add 260 ndash Validation and Control of Special Processes
Add 270 ndash IM amp TE
Add 460 ndash Add Form 542
Add 470 ndash Add 473 ndash 476
Add 500 ndash Requirements for APQP
Add 520 ndash NADCAP Certification
Add 530 ndash Contingency Plans
Add 540 ndash Supplier Performance Rating
REVISION HISTORY
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 3 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
ANSINCSL Z5403 Requirements for Calibration of Measuring and Test Equipment
AS 6174 Counterfeit Materiel Assuring Acquisition of Authentic and Conforming Materiel
AS13000 Problem Solving Requirements for Suppliers
AS13002 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans
AS9015 Supplier Self Verification Process Delegation Programs
AS9100 Quality Management System Requirements (Aerospace)
AS9102 Aerospace First Article Inspection Requirement
AS9103 Variation Management of Key Characteristics
AS9117 Delegated Product Release Verification
AS9120 Quality Management System Requirements (Stockiest Distributor)
AS9130 Quality System Record Retention
AS9145 Requirements for Advanced Product Quality Planning and Production Part
Approval Process
AS9146 Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation
Space and Defense Organizations
CAP-06-014 Digital Product Definition (DPD) for Suppliers
IAQG International Aerospace Quality Group
ILAC International Laboratory Accreditation Cooperation
ISO 10005 Quality Management Systems - Guideline for Quality Plans
ISO 10012 Measurement management systems Requirements for measurement processes
and measuring equipment
ISO 14001 Environmental Management Standards
ISO 17025 Quality Management System Requirements (Testing and Calibration Lab)
ISO 9001 Quality Management System Requirements
OASIS Online Aerospace Supplier Information System
httpwwwsaeorgPORTAL_CODE=IAQG
OHSAS18001 Occupational Health and Safety System
PRI AC 7004 NADCAP Audit Criteria for Inspection and Test Quality system
REACH Registration Evaluation Authorization and Restriction of Chemicals
RoHS Restriction of Hazardous Substances Directive
SQR 002 Supplier Quality Requirement - Delegated Quality Representative Program
(DQRP)
Form 004 Good Discrepancy Report (GDR)
Form 045 Engineering Query Notes (EQN)
Form 138 Stop Note
Form 191 Change Note (CN)
Form 297 Service Discrepancy Report (SDR)
Form 329 Supplier Corrective Action Report (SCAR)
Form 479 Supplier Request for Change Form
Form 542 Supplier Notice of Escape (NoE)
Compliance Matrix Form
Supplier Acknowledgement
REFERENCE IN SQR
SUPPLIER QUALITY REQUIREMENTS Doc No SQR 001
Revision C Effective Date 01012019
Page 3 of 25
CTRM AC PROPRIETARY DOCUMENT MAY NOT BE REPRODUCED OR DISTRIBUTED WITHOUT EXPRESS WRITTEN PERMISSION OF CTRM AC
PRINTED COPIES ARE CONSIDERED UNCONTROLLED
ANSINCSL Z5403 Requirements for Calibration of Measuring and Test Equipment
AS 6174 Counterfeit Materiel Assuring Acquisition of Authentic and Conforming Materiel
AS13000 Problem Solving Requirements for Suppliers
AS13002 Requirements for Developing and Qualifying Alternate Inspection Frequency Plans
AS9015 Supplier Self Verification Process Delegation Programs
AS9100 Quality Management System Requirements (Aerospace)
AS9102 Aerospace First Article Inspection Requirement
AS9103 Variation Management of Key Characteristics
AS9117 Delegated Product Release Verification
AS9120 Quality Management System Requirements (Stockiest Distributor)
AS9130 Quality System Record Retention
AS9145 Requirements for Advanced Product Quality Planning and Production Part
Approval Process
AS9146 Foreign Object Damage (FOD) Prevention Program - Requirements for Aviation
Space and Defense Organizations
CAP-06-014 Digital Product Definition (DPD) for Suppliers
IAQG International Aerospace Quality Group
ILAC International Laboratory Accreditation Cooperation
ISO 10005 Quality Management Systems - Guideline for Quality Plans
ISO 10012 Measurement management systems Requirements for measurement processes
and measuring equipment
ISO 14001 Environmental Management Standards
ISO 17025 Quality Management System Requirements (Testing and Calibration Lab)
ISO 9001 Quality Management System Requirements
OASIS Online Aerospace Supplier Information System
httpwwwsaeorgPORTAL_CODE=IAQG
OHSAS18001 Occupational Health and Safety System
PRI AC 7004 NADCAP Audit Criteria for Inspection and Test Quality system
REACH Registration Evaluation Authorization and Restriction of Chemicals
RoHS Restriction of Hazardous Substances Directive
SQR 002 Supplier Quality Requirement - Delegated Quality Representative Program
(DQRP)
Form 004 Good Discrepancy Report (GDR)
Form 045 Engineering Query Notes (EQN)
Form 138 Stop Note
Form 191 Change Note (CN)
Form 297 Service Discrepancy Report (SDR)
Form 329 Supplier Corrective Action Report (SCAR)
Form 479 Supplier Request for Change Form
Form 542 Supplier Notice of Escape (NoE)
Compliance Matrix Form
Supplier Acknowledgement
REFERENCE IN SQR
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 2 of 21
10 PURPOSE This procedure establishes requirements for CTRM AC supplierrsquos DPD quality assurancequality control system
20 SCOPE
This document is applicable to all suppliers that are furnished digital data used in supplier DPD MBD systems to produce product(s) or digital data for product acceptance This includes suppliers not governed by Customer DPD requirements This procedure describes the requirements for supplier digital data system controls To use customer furnished datasets as authority for design manufacture and inspection a supplier must be approved to a CTRM AC recognized quality system and comply with this document CTRM AC shall document supplier compliance to these requirements within the CTRM AC Supplier Quality Assurance (SQA) records system and on its approved supplier list These requirements provide the basis for suppliers to create and implement plans user-level procedures and documentation The supplier will have defined and reliable configuration management and QA processes in place reflecting its methods of operation Suppliers are required to maintain the integrity of Digital Product DefinitionModel Based Definition (DPDMBD) type design through all operations as new DPDMBD methods are deployed It is anticipated that suppliers will utilize DPDMBD processes to continuously improve the quality of delivered product The application of this document is required for all phases of design and inspection when customer furnished digital dataset is used in supplier DPDMBD systems to produce product(s) or digital data for product acceptance (including accountable tooling and tooling used for inspection) If a supplier is sending digital dataset to CTRM AC the requirements are obtained from the Procurement Contract Administrator and the purchase order and the supplier must meet applicable data exchange requirements When referenced in the Purchase Order or the General Terms AgreementContract this document is contractual Customer digital datasets will not be issued to suppliers not in compliance with the requirements of this document as evidenced by the supplier DPDMBD approval level recorded in the CTRM AC SQA records system
30 ABBREVIATIONDEFINITIONS AUTHORITY Undisputed source of customer approved type design used for product manufacture and Quality Assurance acceptance with communication access release and change control procedures in place to ensure source integrity CAD (Computer Aided Design) (1) Any computer system or program that supports the design process (2) The use of computers to assist Engineering Design in developing producing and evaluating design data and drawings (For brevity CAD is also referred to as the organization engaged in computer-aided design)
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 3 of 21
CAE (Computer Aided Engineering) The use of computers to develop Engineering data to supplement Engineering Designs used in product production and inspection CAM (Computer Aided Manufacturing) Also known as numerical control (NC) The use of computers and computer data in the development and production of a part (product) including fabrication assembly and installation CATIA Computer-graphics Aided Three-Dimensional Interactive Application A CAD system with interactive graphics design software modules used to create 3D and 2D geometric designs of products CMS (Coordinate Measurement Systems) Also known as computer-aided inspection (CAI) and computer Aided Measurement Systems (CAMS) Measurement equipment such as Coordinate Measuring Machines (CMM) Laser Tracker and Numerical Controlled machinery with inspection probe capability which are used to support inspection activity This includes all portable three-dimensional measuring systems including Portable Arm Measuring Machines Computer-aided Theodolite Laser Tracker and Photogrammetry (including videogrammetry) systems require the supplier to be approved CTE Coefficient of Thermal Expansion CTRM AC CTRM Aero Composites Sdn Bhd DATASET A named compilation of related data made accessible to computerized system DERIVATIVE A reproduction of all or part of an authority dataset Derivatives include paper and Mylar plots tool designs inspection datasets created to analyze as-built designs check templates numerical control (NC) datasetsmedia datasets with nominal values for CMS use QA inspection plans and other extractions (dimensions views etc) for inspectionmeasurement use DIGITAL ARTIFACT Digital model with geometry that matches the CMC software functional capabilities in IGES STEP UG or CATIA formatsCMS equipment must have the ability to import a digital model and through the analysis function create a comparison to theoretical values DPD (Digital Product Definition) The electronic data elements that specify the geometry and all design requirements for a product (including notation and parts lists) and the use of this data throughout an integrated CADCAM and CMS system DPDMBD QUALITY ASSURANCE PLAN A comprehensive document describing the Quality System for management of digital data and DPD processes throughout a supplierrsquos production facility The requirements procedures and process references described in the plan provide the basis for supplier organizations to implement user level procedures and documentation
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 4 of 21
EAR Export Administration Regulations Located in 15 of the Code of Federal Regulations (CFR) Parts 730-774 the EAR implements the export re-export and certain transfers of dual-use and purely commercial items The Bureau of Industry and Security (BIS) under the US Department of Commerce is charged with administering these controls which includes the CCL as well as licensing policy and procedures -OP 17-1140 Export Compliance
ERS (Enhanced Reference System) A permanent reference system established for the life of a tool which is transferred from an existing reference system or created specifically for CMS It is designed to provide a large number of established coordinates This allows rapid and accurate measurement in all areas of the tool FEATURE Any hardware design attribute or characteristic This includes physical portions of hardware such as surface face edge radius hole tab slot pin etc and requirements such as non ndashdestructive testing (NDI) All features require validation to conform the product to the design authority All features have associated notes andor Geometric Dimensioning and Tolerancing (GDampT) Feature Control Frames (FCF) but one note or FCF may refer to several features IGES (Initial Graphics Exchange Specification) The American National Standards Institute (ANSI) Data standard for the exchange of computer graphics generated product definition (no solids) between different manufacturers CADCAM systems ITAR (International Traffic in Arms Regulations) Located in Part 22 of the CFR Sub-parts 120-130 the ITAR implements the AECA and governs the export and temporary import of defense articles and defense services covered by the United States Munitions List (USML) The DDTC is charged with administering these controls ndash OP17-1140 Export Compliance INSPECTION PLAN A description of 2D andor 3D computer generated inspection mediamethods derived from authority DPD datasets used to communicate inspection requirements and media usage to manufacturing and inspection areas Typical plans include engineering and plan configuration traceability overlaysetup instructions and a list andor graphic representation of the features to be inspected LEV (Low End Viewer) An entry level visualization CAD system used to view analyze extract and print dimensional and other required data from the DPD dataset MBD (Model Based Definition) A dataset containing the exact solid its associated3d Geometry and 3D annotation of the products dimensions and tolerances to specify a complete product definition This dataset does not contain a conventional 2D drawing MBD is one possible format of DPD MDD (Master Dimension Definition) A mathematically-controlled surface definition which is computer generated This definition consists of control curves defining the surface in two planes and the information in a logical form necessary to develop the third plane andor any cross section Each surface is uniquely identified by number
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 5 of 21
MDI (Master Dimensions Identifier) A number identifying an array of coordinate data used by design manufacturing and inspection to describe an element of a surface or product configuration The data may be an extraction from an MDD or any CATIAAPT-designed surface MDR (Master Dimension Request) A process used by suppliers without demonstrated DPD capability(s) per requirements of this document to request and receive 3D surface definitions andor inspection media extractions from customer Data format may be printouts disks plots etc with evidence of customer QA acceptance and traceability Supplier shall contact customer Procurement Agent for process instructions MDS (Master Dimension Surface) A computer generated mathematically-controlled CATIA 3D surface definition Each surface is uniquely identified by number MEASUREMENT PLANNING Process to control all measurement activity for parts assemblies or tooling products A team including design manufacturing and measurement (QA) specialists determine the measurement andor validation methods and stage in production for all specified product features Data is collected for both process control and product acceptance Measurement planning seeks continuous improvement and innovative validation methods including integration of manufacturing and measurement operations to reduce defects and cycle time NC Numerically Controlled PAS (Product Acceptance Software) DPD software (including CAD LEV data exchange and CMS systems) used to inspect and accept parts assemblies tooling and systems Note Not embedded or loadable airborne software PCMS Portable Coordinate Measurement Systems PDM STEP Product Data Manager (PDM) dataset(s) in STEP format with Bill of Material (BOM) information (Parts Lists Picture Sheet Data Lists Tool Parts Lists etc) used by customer to define CAE requirements This dataset can be communicated to suppliers in a digital format PHYSICAL ARTIFACT Precision machined part with geometry that matches the CMS software functional capabilities CMS equipment has the ability to repeat precise measurements manually or using a program for comparison of supplier measured data results to know values
PTF (CATIA Program Temporary Fixes) Software changes or additions released by the software manufacturer to correct user application problems before the next major software version is available
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 6 of 21
PROCESS CONTROL Use of in-process checks to determine performance parameters of manufacturing operations Data Collected is used to determine when adjustment is needed to reduce manufacturing variability REDUCED CONTENT DRAWINGDATASET Any DPD design dataset without full dimensioning of product features on a 2D sheet This includes Reduced Dimension Drawings and ldquoSimplified Drawingsrdquo which contain 2D sheets and Model Based Definition which (typically) does not REF (REFERENCE ONLY) Notation indicating features or datasets whose definition is not reliable and not authorized for design manufacture or inspection SQA (Supplier Quality Assurance) CTRM AC Supplier Quality Assurance STEP (Standard for the Exchange of Product model data) Standard developed by International Standards Organization for exchange of digital product data It seeks to improve upon IGES by increasing the ability to transfer entire product life-cycle data
SUPPLIER A manufacturer working under CTRM AC contract(s) producing CTRM AC hardware SUB-TIER SUPPLIER A manufacturer working under supplier contract(s) producing CTRM AC hardware TRANSLATION Translations occur when a digital dataset is changed from its original CAD system format to another CAD CAM and CAI application format and require verification
40 RESPONSIBILITIES AND AUTHORITIES
41 CTRM AC representatives
411 CTRM AC SQA may team up with related department such as Quality
Management System (QMS) Configuration Management personnel to assess sub-tier Suppliers minimal annually to ensure the sub-tier Suppliers systems implemented accordingly to the DPDMBD requirements The audit may be conducted on site or desktop depends on availability
412 CTRM AC representatives CTRM AC customers andor regulatory
authorities representatives have right access to the supplierlsquos DPD QA plan and its applicable documentation and facilityarea
413 CTRM AC representatives shall verify compliance and document the supplierlsquos DPD capabilities
414 CTRM AC representatives shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 7 of 21
42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 8 of 21
d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
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Page 9 of 21
523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
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electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
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evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
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APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
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CAE (Computer Aided Engineering) The use of computers to develop Engineering data to supplement Engineering Designs used in product production and inspection CAM (Computer Aided Manufacturing) Also known as numerical control (NC) The use of computers and computer data in the development and production of a part (product) including fabrication assembly and installation CATIA Computer-graphics Aided Three-Dimensional Interactive Application A CAD system with interactive graphics design software modules used to create 3D and 2D geometric designs of products CMS (Coordinate Measurement Systems) Also known as computer-aided inspection (CAI) and computer Aided Measurement Systems (CAMS) Measurement equipment such as Coordinate Measuring Machines (CMM) Laser Tracker and Numerical Controlled machinery with inspection probe capability which are used to support inspection activity This includes all portable three-dimensional measuring systems including Portable Arm Measuring Machines Computer-aided Theodolite Laser Tracker and Photogrammetry (including videogrammetry) systems require the supplier to be approved CTE Coefficient of Thermal Expansion CTRM AC CTRM Aero Composites Sdn Bhd DATASET A named compilation of related data made accessible to computerized system DERIVATIVE A reproduction of all or part of an authority dataset Derivatives include paper and Mylar plots tool designs inspection datasets created to analyze as-built designs check templates numerical control (NC) datasetsmedia datasets with nominal values for CMS use QA inspection plans and other extractions (dimensions views etc) for inspectionmeasurement use DIGITAL ARTIFACT Digital model with geometry that matches the CMC software functional capabilities in IGES STEP UG or CATIA formatsCMS equipment must have the ability to import a digital model and through the analysis function create a comparison to theoretical values DPD (Digital Product Definition) The electronic data elements that specify the geometry and all design requirements for a product (including notation and parts lists) and the use of this data throughout an integrated CADCAM and CMS system DPDMBD QUALITY ASSURANCE PLAN A comprehensive document describing the Quality System for management of digital data and DPD processes throughout a supplierrsquos production facility The requirements procedures and process references described in the plan provide the basis for supplier organizations to implement user level procedures and documentation
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EAR Export Administration Regulations Located in 15 of the Code of Federal Regulations (CFR) Parts 730-774 the EAR implements the export re-export and certain transfers of dual-use and purely commercial items The Bureau of Industry and Security (BIS) under the US Department of Commerce is charged with administering these controls which includes the CCL as well as licensing policy and procedures -OP 17-1140 Export Compliance
ERS (Enhanced Reference System) A permanent reference system established for the life of a tool which is transferred from an existing reference system or created specifically for CMS It is designed to provide a large number of established coordinates This allows rapid and accurate measurement in all areas of the tool FEATURE Any hardware design attribute or characteristic This includes physical portions of hardware such as surface face edge radius hole tab slot pin etc and requirements such as non ndashdestructive testing (NDI) All features require validation to conform the product to the design authority All features have associated notes andor Geometric Dimensioning and Tolerancing (GDampT) Feature Control Frames (FCF) but one note or FCF may refer to several features IGES (Initial Graphics Exchange Specification) The American National Standards Institute (ANSI) Data standard for the exchange of computer graphics generated product definition (no solids) between different manufacturers CADCAM systems ITAR (International Traffic in Arms Regulations) Located in Part 22 of the CFR Sub-parts 120-130 the ITAR implements the AECA and governs the export and temporary import of defense articles and defense services covered by the United States Munitions List (USML) The DDTC is charged with administering these controls ndash OP17-1140 Export Compliance INSPECTION PLAN A description of 2D andor 3D computer generated inspection mediamethods derived from authority DPD datasets used to communicate inspection requirements and media usage to manufacturing and inspection areas Typical plans include engineering and plan configuration traceability overlaysetup instructions and a list andor graphic representation of the features to be inspected LEV (Low End Viewer) An entry level visualization CAD system used to view analyze extract and print dimensional and other required data from the DPD dataset MBD (Model Based Definition) A dataset containing the exact solid its associated3d Geometry and 3D annotation of the products dimensions and tolerances to specify a complete product definition This dataset does not contain a conventional 2D drawing MBD is one possible format of DPD MDD (Master Dimension Definition) A mathematically-controlled surface definition which is computer generated This definition consists of control curves defining the surface in two planes and the information in a logical form necessary to develop the third plane andor any cross section Each surface is uniquely identified by number
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MDI (Master Dimensions Identifier) A number identifying an array of coordinate data used by design manufacturing and inspection to describe an element of a surface or product configuration The data may be an extraction from an MDD or any CATIAAPT-designed surface MDR (Master Dimension Request) A process used by suppliers without demonstrated DPD capability(s) per requirements of this document to request and receive 3D surface definitions andor inspection media extractions from customer Data format may be printouts disks plots etc with evidence of customer QA acceptance and traceability Supplier shall contact customer Procurement Agent for process instructions MDS (Master Dimension Surface) A computer generated mathematically-controlled CATIA 3D surface definition Each surface is uniquely identified by number MEASUREMENT PLANNING Process to control all measurement activity for parts assemblies or tooling products A team including design manufacturing and measurement (QA) specialists determine the measurement andor validation methods and stage in production for all specified product features Data is collected for both process control and product acceptance Measurement planning seeks continuous improvement and innovative validation methods including integration of manufacturing and measurement operations to reduce defects and cycle time NC Numerically Controlled PAS (Product Acceptance Software) DPD software (including CAD LEV data exchange and CMS systems) used to inspect and accept parts assemblies tooling and systems Note Not embedded or loadable airborne software PCMS Portable Coordinate Measurement Systems PDM STEP Product Data Manager (PDM) dataset(s) in STEP format with Bill of Material (BOM) information (Parts Lists Picture Sheet Data Lists Tool Parts Lists etc) used by customer to define CAE requirements This dataset can be communicated to suppliers in a digital format PHYSICAL ARTIFACT Precision machined part with geometry that matches the CMS software functional capabilities CMS equipment has the ability to repeat precise measurements manually or using a program for comparison of supplier measured data results to know values
PTF (CATIA Program Temporary Fixes) Software changes or additions released by the software manufacturer to correct user application problems before the next major software version is available
COMPANY APPROVED
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
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PROCESS CONTROL Use of in-process checks to determine performance parameters of manufacturing operations Data Collected is used to determine when adjustment is needed to reduce manufacturing variability REDUCED CONTENT DRAWINGDATASET Any DPD design dataset without full dimensioning of product features on a 2D sheet This includes Reduced Dimension Drawings and ldquoSimplified Drawingsrdquo which contain 2D sheets and Model Based Definition which (typically) does not REF (REFERENCE ONLY) Notation indicating features or datasets whose definition is not reliable and not authorized for design manufacture or inspection SQA (Supplier Quality Assurance) CTRM AC Supplier Quality Assurance STEP (Standard for the Exchange of Product model data) Standard developed by International Standards Organization for exchange of digital product data It seeks to improve upon IGES by increasing the ability to transfer entire product life-cycle data
SUPPLIER A manufacturer working under CTRM AC contract(s) producing CTRM AC hardware SUB-TIER SUPPLIER A manufacturer working under supplier contract(s) producing CTRM AC hardware TRANSLATION Translations occur when a digital dataset is changed from its original CAD system format to another CAD CAM and CAI application format and require verification
40 RESPONSIBILITIES AND AUTHORITIES
41 CTRM AC representatives
411 CTRM AC SQA may team up with related department such as Quality
Management System (QMS) Configuration Management personnel to assess sub-tier Suppliers minimal annually to ensure the sub-tier Suppliers systems implemented accordingly to the DPDMBD requirements The audit may be conducted on site or desktop depends on availability
412 CTRM AC representatives CTRM AC customers andor regulatory
authorities representatives have right access to the supplierlsquos DPD QA plan and its applicable documentation and facilityarea
413 CTRM AC representatives shall verify compliance and document the supplierlsquos DPD capabilities
414 CTRM AC representatives shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
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42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
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523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
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electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
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evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 21 of 21
APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 4 of 21
EAR Export Administration Regulations Located in 15 of the Code of Federal Regulations (CFR) Parts 730-774 the EAR implements the export re-export and certain transfers of dual-use and purely commercial items The Bureau of Industry and Security (BIS) under the US Department of Commerce is charged with administering these controls which includes the CCL as well as licensing policy and procedures -OP 17-1140 Export Compliance
ERS (Enhanced Reference System) A permanent reference system established for the life of a tool which is transferred from an existing reference system or created specifically for CMS It is designed to provide a large number of established coordinates This allows rapid and accurate measurement in all areas of the tool FEATURE Any hardware design attribute or characteristic This includes physical portions of hardware such as surface face edge radius hole tab slot pin etc and requirements such as non ndashdestructive testing (NDI) All features require validation to conform the product to the design authority All features have associated notes andor Geometric Dimensioning and Tolerancing (GDampT) Feature Control Frames (FCF) but one note or FCF may refer to several features IGES (Initial Graphics Exchange Specification) The American National Standards Institute (ANSI) Data standard for the exchange of computer graphics generated product definition (no solids) between different manufacturers CADCAM systems ITAR (International Traffic in Arms Regulations) Located in Part 22 of the CFR Sub-parts 120-130 the ITAR implements the AECA and governs the export and temporary import of defense articles and defense services covered by the United States Munitions List (USML) The DDTC is charged with administering these controls ndash OP17-1140 Export Compliance INSPECTION PLAN A description of 2D andor 3D computer generated inspection mediamethods derived from authority DPD datasets used to communicate inspection requirements and media usage to manufacturing and inspection areas Typical plans include engineering and plan configuration traceability overlaysetup instructions and a list andor graphic representation of the features to be inspected LEV (Low End Viewer) An entry level visualization CAD system used to view analyze extract and print dimensional and other required data from the DPD dataset MBD (Model Based Definition) A dataset containing the exact solid its associated3d Geometry and 3D annotation of the products dimensions and tolerances to specify a complete product definition This dataset does not contain a conventional 2D drawing MBD is one possible format of DPD MDD (Master Dimension Definition) A mathematically-controlled surface definition which is computer generated This definition consists of control curves defining the surface in two planes and the information in a logical form necessary to develop the third plane andor any cross section Each surface is uniquely identified by number
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 5 of 21
MDI (Master Dimensions Identifier) A number identifying an array of coordinate data used by design manufacturing and inspection to describe an element of a surface or product configuration The data may be an extraction from an MDD or any CATIAAPT-designed surface MDR (Master Dimension Request) A process used by suppliers without demonstrated DPD capability(s) per requirements of this document to request and receive 3D surface definitions andor inspection media extractions from customer Data format may be printouts disks plots etc with evidence of customer QA acceptance and traceability Supplier shall contact customer Procurement Agent for process instructions MDS (Master Dimension Surface) A computer generated mathematically-controlled CATIA 3D surface definition Each surface is uniquely identified by number MEASUREMENT PLANNING Process to control all measurement activity for parts assemblies or tooling products A team including design manufacturing and measurement (QA) specialists determine the measurement andor validation methods and stage in production for all specified product features Data is collected for both process control and product acceptance Measurement planning seeks continuous improvement and innovative validation methods including integration of manufacturing and measurement operations to reduce defects and cycle time NC Numerically Controlled PAS (Product Acceptance Software) DPD software (including CAD LEV data exchange and CMS systems) used to inspect and accept parts assemblies tooling and systems Note Not embedded or loadable airborne software PCMS Portable Coordinate Measurement Systems PDM STEP Product Data Manager (PDM) dataset(s) in STEP format with Bill of Material (BOM) information (Parts Lists Picture Sheet Data Lists Tool Parts Lists etc) used by customer to define CAE requirements This dataset can be communicated to suppliers in a digital format PHYSICAL ARTIFACT Precision machined part with geometry that matches the CMS software functional capabilities CMS equipment has the ability to repeat precise measurements manually or using a program for comparison of supplier measured data results to know values
PTF (CATIA Program Temporary Fixes) Software changes or additions released by the software manufacturer to correct user application problems before the next major software version is available
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 6 of 21
PROCESS CONTROL Use of in-process checks to determine performance parameters of manufacturing operations Data Collected is used to determine when adjustment is needed to reduce manufacturing variability REDUCED CONTENT DRAWINGDATASET Any DPD design dataset without full dimensioning of product features on a 2D sheet This includes Reduced Dimension Drawings and ldquoSimplified Drawingsrdquo which contain 2D sheets and Model Based Definition which (typically) does not REF (REFERENCE ONLY) Notation indicating features or datasets whose definition is not reliable and not authorized for design manufacture or inspection SQA (Supplier Quality Assurance) CTRM AC Supplier Quality Assurance STEP (Standard for the Exchange of Product model data) Standard developed by International Standards Organization for exchange of digital product data It seeks to improve upon IGES by increasing the ability to transfer entire product life-cycle data
SUPPLIER A manufacturer working under CTRM AC contract(s) producing CTRM AC hardware SUB-TIER SUPPLIER A manufacturer working under supplier contract(s) producing CTRM AC hardware TRANSLATION Translations occur when a digital dataset is changed from its original CAD system format to another CAD CAM and CAI application format and require verification
40 RESPONSIBILITIES AND AUTHORITIES
41 CTRM AC representatives
411 CTRM AC SQA may team up with related department such as Quality
Management System (QMS) Configuration Management personnel to assess sub-tier Suppliers minimal annually to ensure the sub-tier Suppliers systems implemented accordingly to the DPDMBD requirements The audit may be conducted on site or desktop depends on availability
412 CTRM AC representatives CTRM AC customers andor regulatory
authorities representatives have right access to the supplierlsquos DPD QA plan and its applicable documentation and facilityarea
413 CTRM AC representatives shall verify compliance and document the supplierlsquos DPD capabilities
414 CTRM AC representatives shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 7 of 21
42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 8 of 21
d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 9 of 21
523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 10 of 21
electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 11 of 21
require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 12 of 21
5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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Doc No CAP06-014
Issue I
Page 13 of 21
12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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Doc No CAP06-014
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Page 14 of 21
company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
COMPANY APPROVED
PROCEDURE
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
COMPANY APPROVED
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Doc No CAP06-014
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Page 16 of 21
4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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Doc No CAP06-014
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
COMPANY APPROVED
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
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Page 18 of 21
evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
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APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
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MDI (Master Dimensions Identifier) A number identifying an array of coordinate data used by design manufacturing and inspection to describe an element of a surface or product configuration The data may be an extraction from an MDD or any CATIAAPT-designed surface MDR (Master Dimension Request) A process used by suppliers without demonstrated DPD capability(s) per requirements of this document to request and receive 3D surface definitions andor inspection media extractions from customer Data format may be printouts disks plots etc with evidence of customer QA acceptance and traceability Supplier shall contact customer Procurement Agent for process instructions MDS (Master Dimension Surface) A computer generated mathematically-controlled CATIA 3D surface definition Each surface is uniquely identified by number MEASUREMENT PLANNING Process to control all measurement activity for parts assemblies or tooling products A team including design manufacturing and measurement (QA) specialists determine the measurement andor validation methods and stage in production for all specified product features Data is collected for both process control and product acceptance Measurement planning seeks continuous improvement and innovative validation methods including integration of manufacturing and measurement operations to reduce defects and cycle time NC Numerically Controlled PAS (Product Acceptance Software) DPD software (including CAD LEV data exchange and CMS systems) used to inspect and accept parts assemblies tooling and systems Note Not embedded or loadable airborne software PCMS Portable Coordinate Measurement Systems PDM STEP Product Data Manager (PDM) dataset(s) in STEP format with Bill of Material (BOM) information (Parts Lists Picture Sheet Data Lists Tool Parts Lists etc) used by customer to define CAE requirements This dataset can be communicated to suppliers in a digital format PHYSICAL ARTIFACT Precision machined part with geometry that matches the CMS software functional capabilities CMS equipment has the ability to repeat precise measurements manually or using a program for comparison of supplier measured data results to know values
PTF (CATIA Program Temporary Fixes) Software changes or additions released by the software manufacturer to correct user application problems before the next major software version is available
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PROCESS CONTROL Use of in-process checks to determine performance parameters of manufacturing operations Data Collected is used to determine when adjustment is needed to reduce manufacturing variability REDUCED CONTENT DRAWINGDATASET Any DPD design dataset without full dimensioning of product features on a 2D sheet This includes Reduced Dimension Drawings and ldquoSimplified Drawingsrdquo which contain 2D sheets and Model Based Definition which (typically) does not REF (REFERENCE ONLY) Notation indicating features or datasets whose definition is not reliable and not authorized for design manufacture or inspection SQA (Supplier Quality Assurance) CTRM AC Supplier Quality Assurance STEP (Standard for the Exchange of Product model data) Standard developed by International Standards Organization for exchange of digital product data It seeks to improve upon IGES by increasing the ability to transfer entire product life-cycle data
SUPPLIER A manufacturer working under CTRM AC contract(s) producing CTRM AC hardware SUB-TIER SUPPLIER A manufacturer working under supplier contract(s) producing CTRM AC hardware TRANSLATION Translations occur when a digital dataset is changed from its original CAD system format to another CAD CAM and CAI application format and require verification
40 RESPONSIBILITIES AND AUTHORITIES
41 CTRM AC representatives
411 CTRM AC SQA may team up with related department such as Quality
Management System (QMS) Configuration Management personnel to assess sub-tier Suppliers minimal annually to ensure the sub-tier Suppliers systems implemented accordingly to the DPDMBD requirements The audit may be conducted on site or desktop depends on availability
412 CTRM AC representatives CTRM AC customers andor regulatory
authorities representatives have right access to the supplierlsquos DPD QA plan and its applicable documentation and facilityarea
413 CTRM AC representatives shall verify compliance and document the supplierlsquos DPD capabilities
414 CTRM AC representatives shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
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42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
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d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
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523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
COMPANY APPROVED
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electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
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APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
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PROCESS CONTROL Use of in-process checks to determine performance parameters of manufacturing operations Data Collected is used to determine when adjustment is needed to reduce manufacturing variability REDUCED CONTENT DRAWINGDATASET Any DPD design dataset without full dimensioning of product features on a 2D sheet This includes Reduced Dimension Drawings and ldquoSimplified Drawingsrdquo which contain 2D sheets and Model Based Definition which (typically) does not REF (REFERENCE ONLY) Notation indicating features or datasets whose definition is not reliable and not authorized for design manufacture or inspection SQA (Supplier Quality Assurance) CTRM AC Supplier Quality Assurance STEP (Standard for the Exchange of Product model data) Standard developed by International Standards Organization for exchange of digital product data It seeks to improve upon IGES by increasing the ability to transfer entire product life-cycle data
SUPPLIER A manufacturer working under CTRM AC contract(s) producing CTRM AC hardware SUB-TIER SUPPLIER A manufacturer working under supplier contract(s) producing CTRM AC hardware TRANSLATION Translations occur when a digital dataset is changed from its original CAD system format to another CAD CAM and CAI application format and require verification
40 RESPONSIBILITIES AND AUTHORITIES
41 CTRM AC representatives
411 CTRM AC SQA may team up with related department such as Quality
Management System (QMS) Configuration Management personnel to assess sub-tier Suppliers minimal annually to ensure the sub-tier Suppliers systems implemented accordingly to the DPDMBD requirements The audit may be conducted on site or desktop depends on availability
412 CTRM AC representatives CTRM AC customers andor regulatory
authorities representatives have right access to the supplierlsquos DPD QA plan and its applicable documentation and facilityarea
413 CTRM AC representatives shall verify compliance and document the supplierlsquos DPD capabilities
414 CTRM AC representatives shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
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42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
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d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
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523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
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electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
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evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
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APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
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42 Supply Chain Department The CTRM AC Supply Chain Department shall be responsible to flow down these requirements to the suppliers through Purchase Order Statement Of Work (SOW) or contract if applicable
43 CTRM AC supplierssub-tier suppliers
The CTRM AC supplierssub-tier suppliers shall ensure all requirements addressed within this procedure are met fulfilled and implemented
50 PROCEDURES
51 General Requirements 511 The supplier supplier sub division and supplier sub-tiers shall develop and
maintain a comprehensive DPDMBD Quality Assurance Plan and procedures to assure integrity of product andor tooling The plan shall insure configuration is maintained throughout the supplierrsquos QMS from receipt of customer data through creation of derivatives to product acceptance and process improvement
512 This plan shall specifically address the processes and techniques unique to
all DPDMBD processes including the delivery of authority data to measurement users in design manufacturing and quality organizations for product acceptance and process control
513 The supplierrsquos documented process shall specify all departmental organizations responsible for performance of CADCAMCAI operations including organizations responsible for the delivery of Customer data or supplier derived data to sub-tier suppliers
514 It is recommended that supplier DPDMBD Quality Assurance Plans describe
a single consistent configuration management and QA process to meet all customer regulatory agency DPDMBD requirements This plan shall remain in effect throughout the life of the contract
515 Customer reserves the right to survey andor review the supplierrsquos DPDMBD
system to verify effectiveness of the supplierrsquos DPDMBD Quality Assurance Plan and procedures
516 Elements of the DPDMBD Quality Assurance Plan shall address but not be limited to the following elements in 51 through 512
517 Overall authority for the DPDMBD QA Plan shall be defined as a Quality
organization responsibility with procedures for change control and maintenance The authority and responsibility for each element of the DPDMBD QA Plan shall be defined and documented to assure consistent implementation The supplier shall notify their Customer Supplier Quality Rep within 30 calendar days of implementing changes to
a The documented DPD Processess
b CATIA synchronization
c CAD CAM CAI software additions updates or changes
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d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
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523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
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electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
COMPANY APPROVED
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Page 18 of 21
evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
COMPANY APPROVED
PROCEDURE
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
COMPANY APPROVED
PROCEDURE
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 20 of 21
70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
COMPANY APPROVED
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 21 of 21
APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 8 of 21
d Addition of new Coordinate Measurement System (CMS)
518 The supplier shall include a flow diagram or equivalent in their plan that includes process ownership and graphically depicts the flow of data through the DPDMBD system from receipt of customer provided digital data through the product life cycle (ie final inspection)
a The flow diagram shall identify the documented DPD processes andor work instructions associated with control of the datasets and derivatives
b In lieu of flow diagram the supplier may provide a complete relational diagram of their internal procedures to the requirements of this document
52 Configuration Management and Media Security
521 Configuration Management and Traceability - The supplier shall develop
and maintain procedures to ensure the configuration of all customer provided datasets supplier created CADCAMCAI datasets type design tool designs and datasets sent to sub-tier suppliers used in fabrication or inspection of products These procedures shall include the following 1 A formal release process of DPD which ensures that only current
authorized DPD datasets are available for use in production and inspection CADCAM Software
2 The supplier shall ensure planning and all derivative DPD data that is released is traceable to the customer authority dataset(s) it was created from with derivatives stored and retained as part of the acceptance package
3 Supplier shall demonstrate traceability to the current authority and any derivative dataset including file name and file extension Derivatives shall have revision control in addition to producttooling revision
4 A documented process for change control and retention for all authority datasets and dataset derivatives
5 A documented process that includes segregation storage and retention of noncurrent (obsolete) authority dataset derivatives
6 Supplier shall have a documented process to generate digitized manufacturinginspection data from customer provided full scale engineering Mylar plots or from any authorized physical representation This process shall ensure integrity of derived dimensions and include review release and configuration control of digitized data
522 The supplier shall develop and maintain procedures for configuration
identification and control of CAM software datasets Objective evidence for verification of numerically controlled machinery and dataset performance must be obtained no later than first production use and is required for release for production
COMPANY APPROVED
PROCEDURE
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TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
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523 Datasets will be provided in the design format designated by the customer for the program under contract Note This will be primarily be native Computer-graphics Aided Three -
Dimensional Interactive Application (CATIA) V5 native CATIA V4 and in some cases Initial Graphics Exchange Specification (IGES) depending upon program design parameters
524 Media Security - The supplier shall develop and maintain documented
procedures used to insure the integrity and security of customer supplier digital datasets supplier extracted data andor supplier generated definition data 1 These procedures shall include requirements for
a Secure storage and retention of customer provided DPD supplier
created DPD derivatives and digital product acceptance datasets
b The supplier shall assure datasets found discrepant are suspended from use and manufacture is contacted for disposition
c Access and archiving procedures with readwrite protection including passwords which ensure access control This includes authority datasets derivatives digital inspection media used for product acceptance
d Encryption protection for sendingreceiving of electronically transmitted data
e Establishing and maintaining a secure data backup and storage system including remote storage and a disaster recovery process for authority datasets derivatives and digital inspection media used for product acceptance
f Access control with permission andor password protection shall be established in order to ensure that customer provided datasets shall not be inadvertently modified This process shall include derivative datasets released for manufacturing and inspection
g Supplier shall have a process to manage (additionremoval) of supplier employee assess to end user customer technical data systems such as REDARS Enovia Team Center cFolders etc
525 The supplier shall provide a system for formal release of digital datasets which ensures that only authority datasets are available for use in production and inspection A record of the key identifiers of customer authority datasets (drawing sheet revision level andor dataset name) and those key identities and naming conventions created for authority supplier derivatives must be readily available during measurement verification and data analysis processes for product acceptance by supplier sub-tier and customer QA representatives 1 A system for change accountability and configuration management for
all datasets and dataset derivatives (including graphicalgeometric
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 10 of 21
electronic data Computer Aided Engineering (CAE) datasets and supplier hardcopy reports) will be maintained by the supplier
2 The supplier shall comply with and reference in their DPDMBD Quality Plan applicable customer document(s) defining the authority status of geometric elements within customer furnished digital datasets
53 Product Acceptance Software (PAS) Validation
531 The supplier shall document and maintain PAS procedures for control of Product Acceptance Software (PAS)PAS includes software used in the acceptance of special tooling and products 1 Supplier must document and maintain PAS procedures and reference
applicable documents in their DPDMBD Quality Assurance Plan Procedures provide for identification of software name software version and validation results used for all Quality Assurance (QA) applications All changes to PAS are documented and approved by supplierrsquos QA
2 Supplier will develop and maintain procedures for reporting tracking and resolving software related product acceptance problems
3 Procedures will be documented and maintained to prevent unauthorized changes to limit personnel access to software files separate archives for Masters and duplicates
4 Supplier PAS must be verified prior to product acceptance andor manufacturing use The supplier shall establish and maintain a procedure and validation plan independent of the software developer to determine that the software and subsequent revisions accomplishes its intended function A formal means of identifying approved PAS is required with configuration control and QA management procedures for relating the PAS to the product being accepted A PAS verification report is required to demonstrate PAS compliance the report shall include the CMS software functional capabilities (ie GDampT etc) that will be used for inspection andor manufacturing of parts andor tooling The PAS verification report shall demonstrate a comparison of measured values to theoretical values (utilizing a physical artifact or embedded software testing ) within a tolerance applicable to the parts andor tooling being manufactured andor inspected Examples of common algorithms include GDampT functions feature construction temperature compensation CAD translations and software that controls hardware
532 Computer Aided Manufacturing Software - When used for inspection (ie CNC on machine probing etc) the supplier shall develop and maintain documented processes for configuration identification and control of CAM software and must meet the requirements of section 531Supplier must verify numerically controlled software prior to product acceptance and maintain records
533 Supplier Developed Software - Software developed by suppliers requires plans and instructions for building configuration management loading and testing of code Supplier developed software and subsequent revisions will
COMPANY APPROVED
PROCEDURE
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Doc No CAP06-014
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require independent testing and meet the requirements of sections 531 to insure the software accomplishes its intended function
54 Coordinate Measurement Systems
541 Suppliers using CMS Optical Layout Template (OLT) and Plotters for
fabrication andor inspection of customer products (parts and tools) must document their CMS processes Suppliers must comply with the product acceptance software measurement equipment inspection media and training requirements for CMS
542 Additional CMS requirements are stated below and require capability approval by Customer or Nadcap accreditation per section 56
543 The supplier must document inventory of all components used for CMS
measurements that affect the integrity of data collection
544 The supplier and its sub-tier suppliers utilizing CMS and OLT (where applicable) shall have documented procedures for all equipment types to be utilized for inspection of hardware to the CTRM AC Supplier Quality Representative of record for review and approval When the documented procedures have been approved and an on-site verification of the procedures completed by the CTRM AC Representative of record an individual approval shall be granted to the supplier for each type of CMS hardware specified This approval shall be recorded in the CTRM AC Approved Supplier List The documented procedures for each type of equipment shall be developed to include the criteria listed below as well as all supplier specific information
1 Purpose Scope - Overview or statement of specific equipment and its intended use
2 Calibration ndash Supplier shall define calibration intervals and maintain a system for periodic maintenance of measurement equipment The supplier must document inventory of all specific components used for CMS and OLT measurement that could affect the integrity of data collection This inventory should include and not be limited to CMM reference sphere and Laser Tracker target accessories (eg bushings adapters sphere mounts barrod probing drift nest supports etc) all reflector types and weather station equipment Calibration and measurement processes shall be traceable to the National Institute of Standards and Technology (NIST) standard or equivalent and meet original equipment manufacturer requirements
3 Product Acceptance Software ndash Supplier shall perform Product Acceptance Software testing per 53 References
4 Field Checks Probe Calibration Set up ndash Establish criteria for field checks probe calibration set up to ensure data and system accuracy prior to collecting measurement data
COMPANY APPROVED
PROCEDURE
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5 Drift Points Stability ndash When environmental conditions vibration or stability of the product being measured could affect measurement data drift point analysis is required A record of drift points measured and acceptance tolerance used before and after measurements is required as objective evidence
6 Temperature Compensation Scale Factors ndashWhen products are measured in an uncontrolled environment a documented process to compensate for thermal effects on the objects being measured is required The product dimensional characteristics being verified must meet the engineering definition requirements as defined in ASME Y145 Dimensioning and Tolerancing and ANSI B8962 Temperature and Humidity Environment for Dimensional Measurement Objective evidence is required for temperature compensation when using scale bars artifacts or temperature calculation Supplier shall document their temperature compensation process which includes planning for pre post and during measurement survey analysis Although scale bars and artifacts are not required for all applications they can be an effective tool for verification of temperature chane in the object if object scale bar temperatures are monitored closely throughout the measurement survey
7 Establish Coordinate System ndash Establish criteria for changing the coordinate system from a local coordinate system to a part or tool coordinate system (eg tolerances datum targets datum features tooling holes tool enhanced reference system or best fit) Establishment of coordinate systems shall be in accordance with customer engineering definition and ASME Y145 as applicable Best Fit alignment shall not be used unless contractually authorized by end use customer and evidence of authorization shall accompany final inspection reports
8 Multiple Station Set-up Criteria ndash When moving CMS equipment from one location to another or combining CMS equipment during a survey supplier shall document their process and acceptance tolerance A minimum of seven adequately distributed common points used as reference for repositioningadding the CMS equipment during a survey shall be verified and recorded as objective evidence
9 Data Collection Parameters ndash Establish measurement guidelines and specific collection parameters for the CMS equipment prior to collecting measurement data (eg point density point labels timedistance separation parameters apex angles and distance limitations)
10 Data Analysis ndash Establish guidelines for the evaluation of 3D point data to tool engineering engineering datasets point maps or drawings
11 Reports ndash Establish standard process for CMS reports (eg shall include job information coordinate system establishment (alignment verification) object temperature data analysis and measured results point maps) When products are measured in an uncontrolled environment CMS reports shall be include scale bars and drift points Reports shall be in English and in inches unless directed otherwise by customer contract
COMPANY APPROVED
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12 Record Retention ndash Establish standard process for all inspection and test records to be archived and retained per customer contract requirements and provided to the customer upon request
13 Training ndash Suppliers shall define training requirements to assure competence and maintain employee training records including onthe-job-training for all CMS users per 511
14 CTRM AC will recognize suppliers approved by Nadcap for Measurement and Inspection (MampI) Industry Controlled Other Party (ICOP) approvals in addition to or in lieu of Customer approval for the following Nadcap accreditations AC7130 AC71301 ndash Nadcap accredidation for CMM
AC7130 AC71302 ndash Nadcap accredidation for Laser Tracker AC7130 AC71303 ndash Nadcap accedidation for Articulating Arms
55 Internal Quality Audits
551 The supplier shall develop and maintain procedures for auditing all operations annually affecting customer digital datasets and related documentation to assure compliance with contractual requirements software and production part quality standards including the observance of security restrictions The audit plan shall include provisions for audit of sub-tier suppliers using DPD data annually on customer products and tooling The audit plan shall address all requirements of this document to include all CMS equipment and software as noted in section 516
552 Results of all audits will be documented and maintained for review by an
authorized customer representative per contract requirements
56 Procurement Control
561 The supplier shall flow down the requirements of this document to their sub-tier suppliers and document sub-tier supplier compliance when customer authority dataset derivatives are used for product acceptance Flow down to sub-tier shall include International Traffic in Arms Regulations (ITAR) Manufacturing License Agreement (MLA) Manufacturing Agreement (MA) Technical Assistance Agreement (TAA) and Export Adminstration Regulations (EAR) requirements
562 The supplier shall be responsible to the customer for the maintenance
change incorporation use of datasets and observance of security restrictions by their sub-tiers for design manufacturing and inspection as applicable
563 Customer reserves the right to survey andor review the DPD quality
assurance and configuration management systems of these suppliers and requires that customer right of entry at supplier facilities be flowed to said suppliers by appropriate documentary means
564 The supplier is fully responsible for and shall establish procedural controls to
assure CTRM AC DPD transferred (authority and derivatie) between their
COMPANY APPROVED
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company divisions and all levels of sub-tier suppliers shall be in compliance with this document
565 The supplier shall determine scope of DPD sub-tier supplier approvals based on their ability to interpret and maintain control and configuration of DPD data Criteria for selection evaluation and re-evaluation shall be established Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained
566 The supplier shall continue to approve sub-tier suppliers and measurement service providers It is recommended that suppliers recognize the Nadcap MampI accreditation or require sub-tier suppliers to become Nadcap MampI accredited NADCAP accreditation does not relieve suppliers of the responsibility to monitor and measure sub-tier performance
57 Control of Measurement Equipment
571 The supplier will develop and maintain a system for a periodic certification of digital measurement equipment These controls will provide records of dates of certification acceptancerejection and next certification due date Measurement equipment will be physically identified in accordance with certification records This includes all CMS equipment NC (CAM) equipment with calibrated inspection probe capability and plotters (used to produce drawings Mylars or other inspection or tooling media)
58 Inspection Media
581 The supplier shall ensure that all digital measurement operations performed on each part or tool are planned Supplierrsquos QA organizations are responsible at a minimum for digital inspection media measurement instructions and analysis of data for product acceptance Measurement planning shall give consideration to the following activities as appropriate in meeting the specified design requirements 1 Description of method and instructions for validation of each product
feature for first article inspection and documentation of the analysis of inspection and test results used as a basis for all qualityinspection adjustments To validate product features with methods other than dimensional measurement the supplier must document the media andor process used
2 Selections of specific stages of production to perform feature measurements to monitor production capability ensure validation of all specified requirements and integrate manufacturing and measurement processes
3 Analysis and delivery of measurement data for engineering disposition design improvement process control and defect reduction
582 The supplier shall develop and maintain procedures to create inspection
media and other measurement data from DPD databases including delivery and control of the media this will include documented inspection plans andor equivalent procedures that
COMPANY APPROVED
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1 Show data sources independent of manufacturing flows
2 Inspection Media is created by qualified personnel
3 Media review process exist (checker checklist or peerteam review)
4 Inspection Media contais graphics annotations text and GDampT sufficient to illustrate inspection operation and result
5 Coordinate system alignment datum features are defined
6 PartTool set up instructions
7 Media is traceable to authority source and any additional derivative media used Note Derivative datasets will be stored and readily comparable to the authority source
Note Derivative datasets will be stored and readily comparable to the authority source
8 When a supplier uses authority databases for inspection purposes any
data extracted from those datasets used for product acceptance must have visible evidence of supplierrsquos QA acceptance and be under configuration control In addition any output data generated from plots and CMS inspection processes must have evidence of suppliers QA acceptance and be under configuration control Traceability of CMS data back to the original customer authority dataset is required
9 Data or datasets identified as ldquoreference onlyrdquo may not be used for inspection purposes
10 Supplier may use definition of Master Dimension Definition (MDD) Master Dimensions Identifier (MDI) Master Dimension Surface (MDS) or other digital definition including IGES or STEP format as authority for product acceptance when supplied by CTRM AC according to a Master Dimension Request (MDR) process
583 Reduced Content Drawings - DPD datasets with reduced content
including MBD datasets without 2D views may require users at supplier to extract information from dataset sufficient to instruct and document manufacturing and inspection activity for the product A LEV 2D sketchesviews andor datasets may be used to convey manufacturing and inspection information as required to fit the supplierrsquos methods of operation When planning measurements for product acceptance supplierrsquos QA verify that all product design requirements as follows 1 All features identified on the 2D drawing
2 Features of the 3D model not defined by the 2D drawing
3 Fabrication amp manufacturing process specifications
COMPANY APPROVED
PROCEDURE
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4 Flag notes parts list amp other specified requirements
5 SSPrsquos SPECOrsquos and APOrsquos ZSPrsquos
584 Printed Wire Boards (PWB) ndash PWB suppliers that have been provided 100 Customer defined 2D drawings are exempt from MAA1-10009-1 approval
585 Supplier created plotted media - Suppliers creating plots for product
acceptance must have documented processes These procedures shall include the following at a minimum
1 Plotter calibration- Follow OEM process for calibration and adjustment
and independent validation to NIST or equivalent
2 Plotting Environment ndash Equipment located in temperature and humidity controlled environment to meet product requirements (Typically 68deg F with +- 2degF variance)
3 Verification of engineering definition Verification of developed flat pattern and plot verification features
4 Plotted media material ndash should be minimum of 0005 inches thick polyester film Paper plots may be approved on a case by case basis for tolerances greater than +- 010 inches
5 Part number identification and revision ndash Traceability to Customer authority dataset
6 Verification of plotted media - acceptance criteria of plot accuracy prior to stamping and releasing plot to manufacturing or inspection
7 Quality acceptance stamping- Date Temperature Humidity Accuracy and evidence of inspection
8 Accuracy of plots used for inspection ndash Plotted media will be validated prior to use in the environment where they are used (Manufacturing amp Inspection etc) Note The tightest product tolerance that can be reasonably inspected with a Mylar overlay is +- 0030 inch after grid check or defined verification features check has been performed
586 Validation of plot accuracy ndash Check plots for accuracy prior to manufacture and inspection of parts Measure to ensure the accuracy of the grid lines or defined verification features vertically horizontally and diagonally to validate plots Grid lines are usually plotted in 10-inch increments Check the grid lines from the first to the last grid line or defined verification features Grid lines shall be within a tolerance of +- 0020 under 100 inches within +- 0030-010 over 100 inches
587 Environmental Controls ndash Plotting equipment shall be located in a temperature and humidity controlled environment Development and validation of plots will be done in an environmentally controlled area using a real time monitoring system for temperature and relative humidity
COMPANY APPROVED
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Note The tolerance noted in the plot accuracy stamp is the accuracy of the plot at the time it was generated and does not relieve the user the responsibility to validate the plot at the time of use
588 Handling Storage - To maintain media accuracy and stability plots are required to store in
1 A container not less than 3 inches in diameter
2 In a non-condensing moisture and chemical free area
3 Temperature from 65 to 80deg F and relative humidity from 45 to 55 percent
4 Do not expose the media to heat generating sources This may include laser printers computer monitors copy machines air compressors transformers batteries engines and sunlight
5 Do not folds crease or damage in anyway as this also effect the dimensional stability
589 Destruction of ObsoleteUnusable Plot Media - All materials and computing media of any kind containing PROPRIETARY information shall be disposed of by methods that ensure that all proprietary information is destroyed so that none of it can be reconstructed from the residue or remains Disposal methods may include recycling shredding burning etc and are dependent upon the resources at any given companysupplier facility Recycling may be used only where procedures are in place to assure continuous security controls throughout the recycling process
59 Data Exchange Methods
591 The supplier shall document the current level of hardware software and other digital system information (eg Program Temporary Fix (PTF) project files) required to maintain synchronization with customer supplier datasets andor data exchange formats per applicable customer system(s) compatibility requirements This includes CAD LEV data exchange and other computing equipment that receives authority data andor is installedtested by customer Supplier shall comply with the reference applicable synchronization requirements in their DPDMBD quality plan Reference CTRM AC form Reg No 386 Section B
592 Translations ndash When suppliers translate from Native CAD format to alternate formats including CATIA V4 to CATIA V5 suppliers are responsible for all dataset translations used for manufacturing and inspection and must have a clear documented process for each The documented process must include a method to verify the accuracy of translations Suppliers must be able to demonstrate the CAD translation process including verificationinterrogation methods used and the ability to identify known discrepancies 1 Acceptance criteria for accuracy of translated surface profile geometry
tolerance) must be determined by the supplier and must ensure the end product will be within engineering tolerance specification Objective
COMPANY APPROVED
PROCEDURE
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Page 18 of 21
evidence of translation validation must be retained (Typical allowable deviation is 110th of the tightest engineering tolerance)
2 The verification process for translation of datasets containing 3D annotation ie feature control frames dimensions text andor surface geometry must ensure that all intended entities are accounted for in the translated media
3 Suppliers receiving Customer authority STEP format datasets supplemented with a 2D DWF 3D-PDF or SUPPAR STEP formats throughout their product realization and inspection process are not required to perform data translation validation It is strongly recommened data translation validation remain a best practice to mitigate potential errors
510 Tooling 5101 Tool Design - The supplier shall describe procedures to ensure release
acceptance identification security access and change control of tool design and tool inspection datasets Tooling datasetsshall have traceability to current authority engineering and derivative tooling dataset sources The engineering authority dataset(s) shall be identified on the tool design when applicable
5102 The supplier shall ensure that when Tool Design responsibility is flowed
down to sub-tier suppliers the sub-tier supplier will be approved by the supplier
5103 Traceability ndash All digitally defined tools and physical inspection media (check fixtures templates etc) will be traceable to the engineering authority dataset tool design dataset and any tool inspection datasets
5104 Inspection - These tools and tooling media will be accepted and periodically validated to the authority design at a frequency determined to ensure accuracy and repeatability of the tool before use
511 Training and Process Performer
5111 DPD Training ndash Suppliers shall define training requirements to assure
competence and shall maintain employee training records for all DPD system users eg quality IT planning purchasing contract review and manufacturing
5112 The supplier shall ensure that QA personnel and other personnel utilizing
the DPD system have DPD system access and training adequate to perform digital product acceptance activities andor their related process functions including digital inspection media generation performance of inspections and 3D data collection If these activities are performed by individuals other than the suppliersrsquo quality assurance personnel the supplier shall define the specific tasks and responsibilities that are authorized and the corresponding requirements and training necessary to perform those tasks A Training Plan (ie Training Matrix etc) is required to document training requirements and status
COMPANY APPROVED
PROCEDURE
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5113 Training syllabus shall include training criteria necessary to ensure proficiency of process performers eg planning programers quality etc to interpret ASME Y14 Dimensioning and Tolerancing (aka GDampT)
512 Authority and Responsibility of Authorized Customer Quality Assurance
Representatives
5121 The Customer Quality Assurance Representative shall have access to the supplierrsquos DPD QA plan and related documentation
5122 The Customer representative shall verify compliance and document the
supplierrsquos DPD capabilities
5123 The Customer representative shall maintain open lines of communication between customer supplier and sub-tier supplier(s) as required for technical coordination and facilitating changing digital processes to improve product quality
60 REFERENCES AS9102 Aerospace First Article Inspection Requirement MAA1-10009-1 Spirit AeroSystems Inc Document D6-51991 Quality Assurance Standard for Digital Product Definition at Boeing Suppliers Form Reg No 386 Digital Product Definition (DPD) Model Based Definition (MBD)
Checklist Form Reg No 513 Supplier DPD MBD Audit Checklist
COMPANY APPROVED
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70 AMENDMENT RECORDS
Issue Date Description Amendment
by
I 22 Aug
16
Revised and add in requirements as per changes of MAA1-10009-1 from revision F to revision G
Sayeda Nafisah
H 23 Sep
2015
bull Add First Article Inspection per AS9102 as a part of Inspection Media in clause 595
bull Add AS9102 as REFERENCES
Farina
Suhaila
G
18 Sep
2013
Revised and add in requirements as per changes of MAA1-10009-1 from revision D to revision E Clause affected 20 30 513 541 543 544 571 591
Farina Suhaila
F
23 May 2013
bull Add in Form 513 to be used during supplier DPD MBD audit in clause 576
bull Add in Supplier DPD MBD Audit Checklist Form 513 in Clause 60 References
Farina Suhaila
E 18 Dec
2012
bull Add in details for sub tier control in clause 57
bull Add in DPD MBD approval for sub tier in Appendix 1
bull Add in KAL DPD SQAR in clause 60 References
Farina Suhaila
D 01 Dec
2011
bull Added lsquoTranslationrsquo in Definition
bull Revise 41 42 517 532 text
bull Added para 54 CMS as new Renumbered remaining paras to 55 to 512
bull Delete 582 and 583 in its entirely and reformatted remaining numbers
bull Revised step formatting in para 5101 and added 5102 as new
bull Add D6-51991 in section 60
bull Revise form Reg 386 to include Attachment A to F per MAA1-10009-1 Rev D
Ho Yick Hong
C 23 Sep
2010
Added ldquoMBDrdquo after each ldquoDPBrdquo callout Revised ldquoDPDrdquo to digital dataset Added ldquoCTErdquo ldquoNC and ldquoPCMSrdquo in section 30 Revise 522 and 523 Revise ldquoDPDrdquo to ldquodigital datasetrdquo in 525 527 545 and 551 Revise 563 582c and 59 Revise 5102 as section 58 Add sentence 5111
Ho Yick Hong
COMPANY APPROVED
PROCEDURE
Aero Composites CAP
TITLE DIGITAL PRODUCT DEFINITION (DPD) FOR
SUPPLIERS
Doc No CAP06-014
Issue I
Page 21 of 21
APPENDIX 1 ((DPD MBD APPROVAL FOR SUPPLIER)
FLOW CHART INPUT PIC
Requestor send DPD MBD checklist
with CAP 06-014 to supplier
Requestor send the complete form
to SQA
SQA and DPD team review DPD
MBD checklist
Supplier fill up DPD MBD checklist
with objective evidence and send
to requestor
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386 (DPD MBD
Checklist)
CAP 06-014 (DPD For
Suppliers)
Form 386
(DPD MBD Checklist)
CAP 06-014
(DPD For Suppliers)
CAP 08-002
Supplier Assessment
Approval amp Control
Requestor
Supplier
Requestor
Supplier
Supplier
Requestor
Requestor
SQA
SQA
CTRM AC rep
SQA
CTRM AC rep
SQA
Does supplier
required
DPD MBD
YES
NO
Evaluation
result
CONFORMING
NON CONFORMING
Supplier is not
approved for DPD
MBD
Proceed with supplier
approval process as
per procedure CAP
08-002