courses

AS9100 Rev D Trainings

What is AS9100 Rev D?

AS9100 is the quality management standard specifically written for the Aerospace and Defense industry. It had long been considered by some entities, such as the Federal Aviation Administration (FAA), that the ISO 9000 series of standards were inadequate in terms of ensuring quality and safety in the “high risk” aerospace industry.

Why is AS9100 so important?

Among the most safety-conscious in the world, the aerospace industry has long recognized the crucial role quality plays in the performance of aviation, space and defense products. Consumer and customer confidence is directly linked to perceptions about the quality of equipment and services manufacturers in this industry offer.

To whom does AS9100 apply?

The industry-wide AS9100 standard was established in 1999 and is the standard to which thousands of suppliers in the aerospace industry are held.

Axeon is certified by Probitas Authentication as an IAQG recognized Training Provider.  The AS9100 Lead Auditor course satisfies the training requirement for AS9100 Aerospace Auditor authentication.  The AATT courses satisfy the Aerospace Auditor Transition Training requirement for the AS9100 Aerospace Auditor authentication.

Companies achieving certification, report:

• Improved product quality and on-time delivery

• More efficient labor utilization

• Increased customer satisfaction in supplier-customer relationships

• Alignment with the International Aerospace Quality Group (IAQG) strategy of having 90% of supply chain certified

Early Bird Pricing

5-Day AS9100D and ISO 9001:2015

Lead Auditor Training Course

 

5 Day Schedule: 7:30 AM – 6:30 PM MST Mon – Thu

7:30 AM – 11:00 AM MST Fri

Audience: Beginner to Advanced
 

This course is certified by Probitas Authentication.  Successful completion of this course satisfies the Lead Auditor training requirement for AS9100 Aerospace Auditor authentication.

Overview

This course prepares you to perform effective Quality Management System (QMS) audits.  You’ll learn how to interpret the verbiage of the ISO 9001:2015 & AS9100D Standard and apply it to your own organization.  We’ll take you through the full audit process, including: audit planning and preparation, opening meetings, document review, interviewing auditees, closing meetings and reporting.  Training includes easy-to-use tools to simplify the auditing process.

This is a practical, how-to course that is not bogged down in academic discussions.  We use case studies, role-plays, and other real-life practice exercises to keep the training active and build competence.

Who Should Attend?

·       quality managers ·       internal auditors
·       management representatives ·       quality consultants
·       audit program managers ·       top management
·       lead auditor candidates ·       those who perform supplier audits

 

Prerequisites

None.  Our students range from seasoned quality professionals to novices.  Our goal is to meet everyone at their current level of competence and increase it.  All students are required to bring their own printed copy of AS9100D.  Most students will be able to obtain a copy from their company.

 

Course Objectives

  • Help you develop the knowledge and skills required to become a Lead Auditor.
  • Improve your understanding of the Aerospace Quality Standard.
  • Learn how to audit to the requirements of the Standard and to your own Standard Operating Procedures (SOPs)
  • Conform to the auditing practices outlined in ISO 19011, ISO 9001 and AS9101
  • Fulfill the lead auditor training requirements of the IAQG Certified Lead Auditor program.

 

Agenda

Day 1

Day 4

Activity

Activity

 

1

Course Introduction

1

Test on TL Unit / Review & Retake

2

History of Quality Management

2

Aerospace Industry Unit

3

AQMS Objectives Quiz

3

Test on AS Unit / Review & Retake

4

In-depth Review of Standard

4

AS9101 Unit

 

Lunch

5

Process-Based Auditing

5

Review of Standard (cont’d)

 

Lunch

6

Exercise: Audit Case Studies (part 1)

6

Audit Role Play Exercise 4

7

AS9101 Quiz / Review & Retake

Day 2

8

Exercise 3: Closing Meeting

1

Exercise: Audit Case Studies (part 2)

9

Class Wrap-Up

2

Learning Game on Pre-assignment

10

Test Prep

3

Test on Standard / Review & Retake

4

AU Module – Part 1. Intro to Auditing

Day 5 

 

Lunch

1

Test Preparation

5

Test on Part 1 / Review & Retake

2

Final Examination

6

Part 2. Preparing for an Audit

7

Test on Part 2 / Review & Retake

8

Part 3. Conducting the Audit

9

Test on Part 3 / Review & Retake

Day 3

1

Audit Role Play Exercise 1

2

Part 4. Completing the Audit

3

Test on Part 4 / Review & Retake

4

Exercise: Writing Audit Findings

Lunch

5

Audit Role Play Exercise 2

6

TL Unit: Leading an Audit Team

5-Day AS9100D and ISO 9001:2015

Lead Auditor Training Course

 

5 Day Schedule: 7:30 AM – 6:30 PM MST Mon – Thu

7:30 AM – 11:00 AM MST Fri

Audience: Beginner to Advanced

This course is certified by Probitas Authentication.  Successful completion of this course satisfies the Lead Auditor training requirement for AS9100 Aerospace Auditor authentication.

Overview

This course prepares you to perform effective Quality Management System (QMS) audits.  You’ll learn how to interpret the verbiage of the ISO 9001:2015 & AS9100D Standard and apply it to your own organization.  We’ll take you through the full audit process, including: audit planning and preparation, opening meetings, document review, interviewing auditees, closing meetings and reporting.  Training includes easy-to-use tools to simplify the auditing process.

This is a practical, how-to course that is not bogged down in academic discussions.  We use case studies, role-plays, and other real-life practice exercises to keep the training active and build competence.

Who Should Attend?

·       quality managers ·       internal auditors
·       management representatives ·       quality consultants
·       audit program managers ·       top management
·       lead auditor candidates ·       those who perform supplier audits

 

Prerequisites

None.  Our students range from seasoned quality professionals to novices.  Our goal is to meet everyone at their current level of competence and increase it.  All students are required to bring their own printed copy of AS9100D.  Most students will be able to obtain a copy from their company.

 

Course Objectives

  • Help you develop the knowledge and skills required to become a Lead Auditor.
  • Improve your understanding of the Aerospace Quality Standard.
  • Learn how to audit to the requirements of the Standard and to your own Standard Operating Procedures (SOPs)
  • Conform to the auditing practices outlined in ISO 19011, ISO 9001 and AS9101
  • Fulfill the lead auditor training requirements of the IAQG Certified Lead Auditor program.

 

Agenda

Day 1

Day 4

Activity

Activity

 

1

Course Introduction

1

Test on TL Unit / Review & Retake

2

History of Quality Management

2

Aerospace Industry Unit

3

AQMS Objectives Quiz

3

Test on AS Unit / Review & Retake

4

In-depth Review of Standard

4

AS9101 Unit

 

Lunch

5

Process-Based Auditing

5

Review of Standard (cont’d)

 

Lunch

6

Exercise: Audit Case Studies (part 1)

6

Audit Role Play Exercise 4

7

AS9101 Quiz / Review & Retake

Day 2

8

Exercise 3: Closing Meeting

1

Exercise: Audit Case Studies (part 2)

9

Class Wrap-Up

2

Learning Game on Pre-assignment

10

Test Prep

3

Test on Standard / Review & Retake

4

AU Module – Part 1. Intro to Auditing

Day 5 

 

Lunch

1

Test Preparation

5

Test on Part 1 / Review & Retake

2

Final Examination

6

Part 2. Preparing for an Audit

7

Test on Part 2 / Review & Retake

8

Part 3. Conducting the Audit

9

Test on Part 3 / Review & Retake

Day 3

1

Audit Role Play Exercise 1

2

Part 4. Completing the Audit

3

Test on Part 4 / Review & Retake

4

Exercise: Writing Audit Findings

Lunch

5

Audit Role Play Exercise 2

6

TL Unit: Leading an Audit Team

3-Day AS9100:2016 Rev D & ISO 9001

Internal Auditor Class

With Live Audits

Days: 3 • CEU Hrs: 2.4
Time: 7:30 a.m.- 6:30 p.m. MST
Audience: Beginner to Advanced

 

Overview

This course prepares you to perform internal QMS audits using industry-proven techniques and to apply the proper interpretation of the ISO standard to real-life audit situations. You’ll follow the full audit process including: audit tools and preparation, opening meetings, audit interviews, closing meetings, and reporting.  This is a very practical class that is not “bogged-down” with academic discussions of quality topics that have limited utility for class attendees.
This Internal Audit class makes extensive use of activities and case studies to help you fully understand the requirements of quality system auditing to the AS9100:2016 Rev D standard. Since people “lock” new understanding into long-term memory much better when they apply it, lecture time is held to a minimum providing you time to grasp and then practice your newly acquired skills in simulated real-life audit situations.

Who Should Attend?

Individuals who will perform audits to AS9100:2016 Rev D Standards or Quality Management Systems, individuals assisting their organizations toward AS9100:2016 Rev D registration, or individuals who are frequently audited should attend this training. Quality directors, managers, engineers, auditors, ISO coordinators, laboratory quality professionals, and anyone engaged in quality audits will benefit from this training.

Prerequisites

There are no required prerequisites.  This course is routinely taught to quality novices and lifetime professionals. All attendees are required to bring their own copy of the AS9100:2016 Rev D Quality Management Standard Requirements for this training course. These will not be provided for you. We strongly advise you bring a “paper” copy.

Course Objectives

  • Prepared to conduct a solo internal audit at successful course completion
  • Fully understand and interpret the AS9100:2016 Rev D requirements.
  • Apply the proper interpretation of the standard in actual audit situations.
  • Understand process auditing tools leading to substantive quality system improvements
  • Tailor an audit interview based on the requirements of the standard and obtain audit evidence from this interview.
  • Follow-up and resolve “audit trails that present themselves during the audit interviews
  • Conduct audits that result in real improvements to the quality system
  • Plan and execute the entire audit process including: audit preparation, opening meetings, auditing, closing meetings, and reporting.

 

Agenda

Day 1

Part 1:  Introductions and Self-Assessment

  1. Course requirements
  2. How to get the most from this experience
  3. Networking with classmates (industry professionals)
  4. Self-assessment of audit skills and internal audit programs Exercise #1

Part 2:  Quality Terminology and Definitions

  1. Quality industry vernacular from AS9100:2009, ISO 19011
  2. Differentiating between Verification and Validation
  3. Understanding Corrective Actions and Risk Management
  4. How to converse with external auditors
  5. Terminology Exercise #2

Part 3:  Requirements of AS9100:2009

  1. Demystifying the AS9100:2016 Rev D standard
  2. Interpreting and cross-referencing the quality standard
  3. Analyzing audit findings
  4. Audit exercises for application of AS9100:2016 Rev D to quality events
  5. Audit Case Studies

Part 4:  The Audit Process:  Roles and Duties

  1. Roles of Auditors, Auditees, and Management during Internal Audits (IAs)
  2. Qualifying Auditors
  3. Duties of the IA staff
  4. Exercise #8: Preparing to be audited-

Day 2

Part 5:  The Audit Process:  Performing the Audit Process

  1. Audit Tools – checklists, process maps, findings, reports
  2. Conducting Audit Interviews Exercise #9
  3. Exercise #10 with Morgan Case Studies

Part 6:  The Audit Process:  Audit Skills and Techniques

  1. Audit Interviewing techniques
  2. Continual improvement techniques
  3. Process Auditing methods
  4. Developing a “continual improvement” attitude in the organization
  5. Exercise #11 Writing Audit Findings
  6. Exercise #12 Evaluating the effectiveness of Audits
  7. Exercise #13 Application of Process Auditing techniques
  8. Review written NCRs and OFIs

Day 3

Part 7:  The Audit Process:  Finalizing the Audit

  1. Developing an Audit Schedule
  2. Conducting Audits- Live Audit
  3. Writing Non-Conformities
  4. Prepare a PEAR form
  5. Writing the audit report
  6. Exercise #14 Writing and audit report
  7. Exercise #15 Writing Non-Conforming Reports
  8. Exercise #16 Conducting a Closing Meeting

Review and Examination of Certificate

3-Day AS9100:2016 Rev D & ISO 9001

Internal Auditor Class

With Live Audits

Days: 3 • CEU Hrs: 2.4
Time: 7:30 a.m.- 5:30 p.m. MST
Audience: Beginner to Advanced

 

Overview

This course prepares you to perform internal QMS audits using industry-proven techniques and to apply the proper interpretation of the ISO standard to real-life audit situations. You’ll follow the full audit process including: audit tools and preparation, opening meetings, audit interviews, closing meetings, and reporting.  This is a very practical class that is not “bogged-down” with academic discussions of quality topics that have limited utility for class attendees.
This Internal Audit class makes extensive use of activities and case studies to help you fully understand the requirements of quality system auditing to the AS9100:2016 Rev D standard. Since people “lock” new understanding into long-term memory much better when they apply it, lecture time is held to a minimum providing you time to grasp and then practice your newly acquired skills in simulated real-life audit situations.

Who Should Attend?

Individuals who will perform audits to AS9100:2016 Rev D Standards or Quality Management Systems, individuals assisting their organizations toward AS9100:2016 Rev D registration, or individuals who are frequently audited should attend this training. Quality directors, managers, engineers, auditors, ISO coordinators, laboratory quality professionals, and anyone engaged in quality audits will benefit from this training.

Prerequisites

There are no required prerequisites.  This course is routinely taught to quality novices and lifetime professionals. All attendees are required to bring their own copy of the AS9100:2016 Rev D Quality Management Standard Requirements for this training course. These will not be provided for you. We strongly advise you bring a “paper” copy.

Course Objectives

  • Prepared to conduct a solo internal audit at successful course completion
  • Fully understand and interpret the AS9100:2016 Rev D requirements.
  • Apply the proper interpretation of the standard in actual audit situations.
  • Understand process auditing tools leading to substantive quality system improvements
  • Tailor an audit interview based on the requirements of the standard and obtain audit evidence from this interview.
  • Follow-up and resolve “audit trails that present themselves during the audit interviews
  • Conduct audits that result in real improvements to the quality system
  • Plan and execute the entire audit process including: audit preparation, opening meetings, auditing, closing meetings, and reporting.

 

Agenda

Day 1

Part 1:  Introductions and Self-Assessment

  1. Course requirements
  2. How to get the most from this experience
  3. Networking with classmates (industry professionals)
  4. Self-assessment of audit skills and internal audit programs Exercise #1

Part 2:  Quality Terminology and Definitions

  1. Quality industry vernacular from AS9100:2009, ISO 19011
  2. Differentiating between Verification and Validation
  3. Understanding Corrective Actions and Risk Management
  4. How to converse with external auditors
  5. Terminology Exercise #2

Part 3:  Requirements of AS9100:2009

  1. Demystifying the AS9100:2016 Rev D standard
  2. Interpreting and cross-referencing the quality standard
  3. Analyzing audit findings
  4. Audit exercises for application of AS9100:2016 Rev D to quality events
  5. Audit Case Studies

Part 4:  The Audit Process:  Roles and Duties

  1. Roles of Auditors, Auditees, and Management during Internal Audits (IAs)
  2. Qualifying Auditors
  3. Duties of the IA staff
  4. Exercise #8: Preparing to be audited-

Day 2

Part 5:  The Audit Process:  Performing the Audit Process

  1. Audit Tools – checklists, process maps, findings, reports
  2. Conducting Audit Interviews Exercise #9
  3. Exercise #10 with Morgan Case Studies

Part 6:  The Audit Process:  Audit Skills and Techniques

  1. Audit Interviewing techniques
  2. Continual improvement techniques
  3. Process Auditing methods
  4. Developing a “continual improvement” attitude in the organization
  5. Exercise #11 Writing Audit Findings
  6. Exercise #12 Evaluating the effectiveness of Audits
  7. Exercise #13 Application of Process Auditing techniques
  8. Review written NCRs and OFIs

Day 3

Part 7:  The Audit Process:  Finalizing the Audit

  1. Developing an Audit Schedule
  2. Conducting Audits- Live Audit
  3. Writing Non-Conformities
  4. Prepare a PEAR form
  5. Writing the audit report
  6. Exercise #14 Writing and audit report
  7. Exercise #15 Writing Non-Conforming Reports
  8. Exercise #16 Conducting a Closing Meeting

Review and Examination of Certificate

2-Day Statistical Process Control (SPC)

Days: 2

Time:  7:30 AM- 4:30 PM MST

AXEON’s training courses begin with your objectives in mind. Before any training begins the instructor must have an objective to deliver your desired outcome. If the course does not have a specific objective, students can go through the motions with little added value. AXEON’s course setup begins with a candid discussion of your needs and expectations with the course instructor to develop specific areas of focus for the class. Below is a general outline for the course and topics that will be covered.

Overview

Statistical process control (SPC) procedures help you monitor process behavior. One of the staple SPC tools used by quality process analysts, improvement associates, inspectors and more is the control chart. Axeon’s statistical process control training will walk you through the details of control charting and other SPC procedures and how to apply them within your organization.

Who Should Attend?

·    Quality & Process Engineers ·    Process Development & Validation Personnel
·    Quality Technicians ·     Manufacturing/Operations Personnel
·    Production Supervisors ·    Process Improvement Personnel
·    SPC Supervisors ·    Supplier Quality Personnel
·    Laboratory Personnel ·    Six Sigma Professionals

 

Agenda

  • Sources of Variation
    • Common and Special Cause Sources
    • Detecting Special Cause Sources
  • Charts: Xbar and R
    • Differences Between Measurements and Averages
    • Computing Control Limits and Charting
  • Other Charts
    • Individuals & Moving Ranges
    • Xbar and S Charts
    • Charts for Short Production Runs
  • Attribute Charts (p, np, c, u)
    Chart Interpretation

    • Type I and Type II Errors
    • Guidelines for Analysis of Charts
    • Out of Control Signals
  • Sensitivity
    • Impact of Sample Size on Chart Sensitivity
    • Determining Sample Size
  • Process Capability
    • Capability ratio – Cr
    • Performance Ratio – Pr
    • Capability Index – Cp
    • Performance Index – Pp
    • Process Capability – CpK
    • The Standard Normal
    • Z Values
    • Computing Proportion Defective

Aerospace Risk Requirements,

AS13004 PFMEA & Control Plans

Risk Management for ISO 31000:2018

Days: 2 

 7:30 AM- 4:30 PM MST

 

Overview

This class teaches participants the Aerospace Risk Requirements (per AS9100, 9110, and 9120) as well as the specific requirements for Operation Risk as defined in AS13004 PFMEA and Control Plans.  The course follows a well-organized, systematic approach to Identify, Assess, and Mitigate Risks that impact Aerospace organizations and the risks to their customers and stakeholders. While Risk Management is a basic requirement of ISO 9001, the Aerospace standards incorporate all of these requirements and add further requirements to make aerospace products and services safe and effective throughout the Supply Chain.  Further, with reduced risks inherent in the Design and Manufacture of aerospace articles, the Costs associated with their manufacture should be reduced.

Who Should Attend

  • Any organization that needs a formal, disciplined approach to the identification, assessment, and management of Risk.
  • Organizations that must meet the requirements–AS9100 Operational Risk Management, and
    AS13004 PFMEA and Control Plans.
  • Quality Managers
  • Management Representatives
  • Engineering Managers
  • Internal and external auditors
  • Design Teams
  • Project Teams

What you will learn

  • How to address Risk-Based Thinking requirements of ISO 9001:2015 and AS9100 (per ISO 31000).
  • How to address the Operational Risk Management requirements of AS9100 (per AS13004).
  • Tools used for Risk Assessment such as DFMEA, Process Flow Diagrams, PFMEAs and Control Plans.
  • How risk management can be applied to any organization, regardless of its products or customers.
  • A means for demonstrating to customers and stakeholders the potential risks associated with products or processes and provide assurance that these have been effectively managed.
  • How to quantify risk as the first step in establishing priorities for your organization.
  • Methods for controlling risks within your Supply Chain

 

AGENDA

Day 1

  • Risk terminology
  • Four-step Risk Management process outlined in ISO 31000
  • Risk-based Thinking requirements of ISO 9001:2015 and AS9100D
  • Strategic vs. process risk management
  • Tools, methods, and a streamlined approach for addressing risk-based thinking requirements.
  • Hands-on exercises

Day 2

  • Aerospace risk terminology
  • Overview of APQP and PPAP risk tools: Process Flow Diagrams, PFMEAs and Control Plans
  • How to develop a Process Flow Diagram (identifying process risks)
  • Guidelines for performing a Process Failure Modes and Effects (FMEA) analysis
  • Creating an effective Control Plan used to manufacture and control and resolve ongoing process risks
  • Detailed hands-on case study developing an FMEA analysis, with tools for completing each stage
  • Requirements for Operational Risk Management
  • Overview of AS13004 – Process Failure Modes and Effects Analysis and Control Plans
  • Guidance on using AS13004 methodology to meet Operational Risk Management requirements

Human Factors

And How to Address Them

Days: 2

Time: 7:30 AM- 4:30 PM MST

Audience: Beginner to Advanced

Overview

Human Factors is a term that appears in the latest versions of several ISO standards, including:

  • ISO 9001:2015 General manufacturing QMS
  • AS9100D:2016  Aerospace QMS
  • ISO 14971:2007 Risk management for medical devices
  • ISO 45001:2018 Occupational health and safety

This course helps you to understand human factors in the context of each standard.  You will learn how to apply the concept of human factors to your management system and address the standard requirements.  You will also receive practical tools, proven methodologies, and helpful tips to make the job easier for you.

As with all of Axeon’s courses, this is a practical, how-to course that is not bogged down in academic discussions.  We use case studies, practice exercises, and learning activities to keep the training activities and build competence.

Who Should Attend?

·     Quality managers Also:
·     Management representatives ·     Quality consultants
·     Quality engineers ·     Those involved in performing corrective actions
·     Safety managers ·     Those involved in medical device risk management
·     Top management ·     Preparation Of Checklists From Process Analysis
·     Regulatory affairs specialists

 

Prerequisites

 

None.  Our students range from seasoned quality professionals to novices. Our goal is to meet everyone at their current level of competence and increase it.

Course Objectives

  • Understand the requirements of human factors in the context of each standard.
  • Learn how to address human factors within your organization’s quality and/or safety management system.
  • Provide practical tools and methods for addressing human factors.

 

Agenda

 

Day 1 

Intro to Human Factors
Review ISO Standard Requirements: 9001, AS9100D, 14971, 45001
Definitions of Human Factors by Standard

Human Factors and Root Cause Analysis
Corrective Action and Human Factors
The 13 Most Common Human Factors
Activity: Applying Human Factors in Corrective Action

Human Factors and Poka-Yoke
Definition & History of Poka-Yoke
Methodology for Poka-Yoke
Activity: Applying Poka-Yoke to Human Factors

Day 2

Human Factors and Health & Safety
Definition of Human Factors in Health & Safety
Human Factors and Ergonomics
How Human Factors influence Safety at Work
Activity: Applying Human Factors to Safety

Human Factors and Medical Devices
Methodology for Considering Human Factors in Risk Assessment
Device Design According to Human Factors Consideration
Human Factors in Post-Market Surveillance

Final Test

2-day AS9145 APQP & PPAP

Advanced Product Quality Planning and Production Part Approval Process

Days: 2

Time: 7:30 AM – 4:30 PM MST

 

Overview

This standard establishes requirements for performing and documenting APQP and PPAP. APQP begins with conceptual product needs and extends through product definition, production planning, product and process validation (i.e., PPAP), product use, and post-delivery service. This standard integrates and collaborates with the requirements of the 9100, 9102, 9103, and 9110 standards.

The requirements specified in this standard are complementary (not alternative) to contractual and applicable statutory and regulatory requirements. Should there be a conflict between the requirements of this standard and applicable statutory or regulatory requirements, the latter shall take precedence.

Learning Objectives 

  • APQP and PPAP terminology
  • APQP general requirements
  • APQP project management
  • APQP phases (1 to 5) requirements
  • PPAP process requirements
  • PPAP file and submission
  • PPAP disposition, submission, recording and resubmission

Who Should Attend?

  • Senior Managers
  • Management Representatives
  • Implementation Teams
  • Internal Auditors

Any others involved in the auditing or implementation of Advanced Product Quality Planning (APQP) activities including Control Plans.

 

Agenda

 

1 Introduction
2 History, Aerospace requirements for APQP/PPAP
3 Activity #1  Terminology
4  AS9145  Clause 4.1 – 4.2  General Requirements, Start-Up
5 Workshop #1  SCMH  Checklists
6 AS9145  Clause 4.3  Phase I Planning
7 Workshop #2
8 AS9145  Clause 4.4  Phase 2  Product Design & Development
9 Workshop #3
10 AS9145  Clause 4.5  Phase 3  Process Design & Development

Day 1

 

Day 2

1 AS9145  Clause 4.5  Phase 3  Process Design & Development
2 Workshop #4
3 AS9145  Clause 4.6  Phase 4  Product & Process Validation
4 AS9145  Clause 4.7  Phase 5  Ongoing Production, Use, Post Delivery
5 Workshop  #5
6 AS9145  Clause 5.1 – 5.4   PPAP
7 Workshop  #6
8 In-Class Case Study

 

2-Day AS9100:2016 Rev D & ISO 9001

Internal Auditor Class

Days: 2 • CEU Hrs: 1.9

Time:  7:30 a.m.- 4:30 p.m. MST

Audience: Beginner to Advanced

Overview 

This course prepares you to perform internal QMS audits using industry-proven techniques and to apply proper interpretation of the ISO standard to real life audit situations. You’ll follow the full audit process including: audit tools and preparation, opening meetings, audit interviews, closing meetings, and reporting.  This is a very practical class that is not “bogged-down” with academic discussions of quality topics that have limited utility for class attendees.

This Internal Audit class makes extensive use of activities and case studies to help you fully understand the requirements of quality system auditing to the AS9100:2016 standard. Since people “lock” new understanding into long-term memory much better when they apply it, lecture time is held to a minimum providing you time to grasp and then practice your newly acquired skills in simulated real-life audit situations.

Who Should Attend?

Individuals who will perform audits to AS9100:2016 Standards or Quality Management Systems, individuals assisting their organizations toward AS9100:2016 registration, or individuals who are frequently audited should attend this training. Quality directors, managers, engineers, auditors, ISO coordinators, laboratory quality professionals, and anyone engaged in quality audits will benefit from this training.

Prerequisites

There are no required prerequisites.  This course is routinely taught to quality novices and life-time professionals. All attendees are required to bring their own copy of the AS9100:2016 Quality Management Standard Requirements to this training course. These will not be provided for you. We strongly advise you bring a “paper” copy.

Course Objectives

  • Prepared to conduct a solo internal audit at successful course completion
  • Fully understand and interpret the AS9100:2016 requirements.
  • Apply the proper interpretation of the standard in actual audit situations.
  • Understand process auditing tools leading to substantive quality system improvements
  • Tailor an audit interview based on the requirements of the standard and obtain audit evidence from this interview.
  • Follow-up and resolve “audit trails that present themselves during the audit interviews
  • Conduct audits that result in real improvements to the quality system
  • Plan and execute the entire audit process including: audit preparation, opening meetings, auditing, closing meetings, and reporting.

Agenda

DAY 1

Part 1:  Introductions and Self-Assessment

  1. Course requirements
  2. How to get the most from this experience
  3. Networking with classmates (industry professionals)
  4. Self-assessment of audit skills and internal audit programs Exercise #1

Part 2:  Quality Terminology and Definitions

  1. Quality industry vernacular from AS9100:2009, ISO 19011
  2. Differentiating between Verification and Validation
  3. Understanding Corrective Actions and Risk Management
  4. How to converse with external auditors
  5. Terminology Exercise #2

Part 3:  Requirements of AS9100:2009

  1. Demystifying the AS9100:2016 Rev D standard
  2. Interpreting and cross-referencing the quality standard
  3. Analyzing audit findings
  4. Audit exercises for the application of AS9100:2016 Rev D to quality events
  5. Audit Case Studies

Part 4:  The Audit Process:  Roles and Duties

  1. Roles of Auditors, Auditees, and Management during Internal Audits (IAs)
  2. Qualifying Auditors
  3. Duties of the IA staff
  4. Exercise #8: Preparing to be audited

DAY 2

Part 5:  The Audit Process:  Performing the Audit Process

  1. Audit Tools – checklists, process maps, findings, reports
  2. Conducting Audit Interviews Exercise #9
  3. Exercise #10 Quality event case studies

Part 6:  The Audit Process:  Audit Skills and Techniques

  1. Audit Interviewing techniques
  2. Continual improvement techniques
  3. Process Auditing methods
  4. Developing a “continual improvement” attitude in the organization
  5. Exercise #11 Writing Audit Findings
  6. Exercise #12 Evaluating the effectiveness of Audits
  7. Exercise #13 Application of Process Auditing techniques

Part 7:  The Audit Process:  Finalizing the Audit

  1. Writing the audit report
  2. Opening and Closing Meetings
  3. Exercise #14 Writing and audit report
  4. Exercise #15 Writing Non-Conforming Reports
  5. Exercise #16 Conducting a Closing Meeting

Review and Examination of Certificate

AS13000 8-D Root Cause Corrective Action

Problem-Solving Requirements for Suppliers Training

Days: 2

Time:  7:30 a.m.- 4:30 p.m. MST

Overview

This class is Root Cause CAPA for Aerospace. If you are a Boeing, Airbus, or other top OEM suppliers you need this class! All suppliers for the top OEM’s are required to have an 8D Practitioner. This training fulfills the training and testing requirements to become an 8D Practitioner.

AS13000 defines the Problem-Solving standard for suppliers within the aero-engine sector, with the Eight Disciplines (8D) problem-solving method being the basis for this standard.

This 2-day course provides students with a comprehensive and standardized set of tools to become an 8D practitioner and meets all the requirements of “training syllabus” (see AS1300 APPENDIX C). Successful application of 8D achieves robust corrective and preventive actions to reduce the risk of repeat occurrences and minimize the cost of poor quality. This is essential to enable long-term customer-supplier relationships and positively contributes towards zero defects and customer satisfaction.

This course includes the practical application of each of the 8D disciplines.

Learning Objectives:

  • Lead and Facilitate an 8D Problem Solving Activity to AS13000 Requirements
  • Complete an AS13000 8D Problem Solving Template
  • Apply a Problem-Solving Toolkit
  • Recognize and deal with issues of Team Dynamics and Challenging People
  • Practice Effective Customer / Stakeholder Management
  • Reduce Risk of Problem Recurrence

Who Should Attend:

This training is a requirement for Aerospace Suppliers of any top OEM. Any employees that will conduct a corrective action or participate as a team member, as well as any individual who would like to gain an in depth understanding of the 8-D process.

Agenda

Day 1

  • Introduction & 8-D Practitioner Requirements
  • Problem Solving Terminology and Definitions
  • Activity #1 Standard Terminology
  • Review of Standard
  • Requirements for an 8-D Practitioner Appendix C
  • Topics: Problem Solving Form Append. A, Team Dynamics, Questioning and Listening Techniques, Basic Tools overview
  • Methods: Appendix B: Questions, Brainstorming, Comparison Sheets, Check Sheets/Talley Sheets, Histograms, Scatter Diagrams, Run and Control Charts, Pareto Analysis, Human Factors, Analysis Techniques, Root Cause Chain
Case Studies:
  • Activity #1.1 Inputs for Process Flow Diagram
  • Activity #1.2 Is/Is Not and 8D Form
  • Case Studies Cont. :
  • Activity #2.1 5W2H Define the Problem
  • Activity #2.2 Define the Problem 8-D form
  • Activity #2.3 PCB CAR Review/8-D D2 & D3
  • Activity #3.1 Ishikawa – Fishbone

Day 2

  • Case Studies Cont. :
  • Activity #2.1 5W2H Define the Problem
  • Activity #2.2 Define the Problem 8-D form
  • Activity #2.3 PCB CAR Review/8-D D2 & D3
  • Activity #3.1 Ishikawa – Fishbone

Maximizing the ROI from your Quality Management System

Days: 1

Time: 7:30 AM-4:30 PM MST

Audience: Top management

Overview 

A Quality Management System is NOT a cost of doing business.  It’s an investment.  And top management should expect to get a financial return on that investment.  However, the Return On Investment (ROI) they receive will be greatly impacted by the level of leadership and commitment they provide concerning the management system.

The newest versions of most ISO management standards have amplified the requirements for top management, in accordance with ISO 9001:2015.  In this highly interactive course, senior managers will learn how to fulfill their new responsibilities, take accountability, and maximize the ROI they get from their management systems.

Why Attend?

This class will help to show the true value of your quality management system and how much it really adds to your bottom line. It will also help your company to increase the ROI of your QMS.

If you want to improve your company’s bottom line or show your boss how much your QMS is already contributing to profits then this class is for you.

Who Should Attend?

  • Top management from organizations with quality, environmental, or safety management systems, including chief executives, general managers, and other senior managers.
  • Quality Managers and/or Management Representatives
  •  Anyone considering implementing an ISO quality system

Course Objectives

  • Understand the new top management ISO requirements and how to accomplish them.
  • Understand the responsibilities that can be delegated to a management representative, and those responsibilities top management must retain.
  • Learn how to maximize the ROI from your management system.
  • Receive practical methods, tools, and tips for using your QMS to enhance organizational performance.
  • Learn the mistakes to avoid that can negatively impact your management system.
  • To provide decision-makers with information that will help them to provide direction for their existing or planned quality management system

 

Agenda

Benefits of a Quality Management System

  • Overview of Potential Benefits, including Return on Investment (ROI)
  • Why Top Management Leadership and Commitment is Important.
  • Creating an Organizational Culture that Supports Quality.

Overview of Quality Principles

  • What is Quality?  What is Quality Management?
  • Top Management Responsibilities (per ISO 9001) and How to Accomplish Them.

How to Maximize the ROI from your QMS

  • ROI Depends on an Organization’s Level of Commitment to its QMS System.
  • Using your QMS processes to ensure Customer Satisfaction and Increase Profitability.
  • Using the Process Approach to Manage Quality (Turtle Diagram).
  • Establishing KPIs and Determining Process Effectiveness.
  • Continuously Improving your QMS.
  • Reducing the Costs of Poor Quality (COPQ).
  • Using Your QMS to Manage Risks and Support Your Strategic Direction.

 

The Five Biggest Mistakes Executives Make with Quality Management

 

Final Test

ITAR & Export Basics

Days: 1

Time: 7:30a.m.-4:30p.m. MST

What are ITAR and EAR?

ITAR (International Traffic in Arms Regulations) and the EAR (Export Administration Regulations) are export control regulations run by different departments of the US Government.  Both of them are designed to help ensure that defense-related technology does not get into the wrong hands.  An export license is a general term for both ITAR and EAR-controlled items in which the US Government has granted permission to transport or sell potentially dangerous items to foreign countries or parties.

Becoming ITAR and EAR Compliant

To be ITAR or EAR compliant, a manufacturer or exporter whose articles or services appear on the USML or CCL lists must register with the U.S. State Department’s Directorate of Defense Trade Controls (DDTC). ITAR and EAR compliance can be problematic for a global corporation because the data related to a specific type of technology may need to be transferred over the Internet or stored locally outside the United States to make business processes flow smoothly. It is the responsibility of the manufacturer or exporter to take the necessary steps to certify that they are in compliance with the regulations.

Export control laws provide for substantial penalties, both civil and criminal.  Failure to comply with ITAR can result in civil fines as high as $500,000 per violation, while criminal penalties include fines of up to $1,000,000 and 10 years imprisonment per violation.  Under EAR, maximum civil fines can reach $250,000 per violation. Criminal penalties can be as high as $1,000,000 and 20 years imprisonment per violation.

ITAR:

The Department of State is responsible for the export and temporary import of defense articles and services governed by 22 U.S.C. 2778 of the Arms Export Control Act and Executive Order 13637. The International Traffic in Arms Regulations (“ITAR,” 22 CFR 120-130) implements the AECA.

The more stringent of the two sets of regulations was written for articles with direct defense-related applications.  Articles specifically designed or otherwise intended for military end-use are enumerated on the United States Munitions List (USML) or the Missile Technology Control Regime (MTCR) Annex and therefore controlled by International Traffic in Arms Regulations (ITAR) which is administered by the Directorate of Defense Trade Controls (DDTC) at the State Department.  Items, services, and information are all covered by the ITAR regulations.  The most controlled items are Significant Military Equipment (SME) which have “capacity for substantial military utility or capability” such as tanks, high explosives, naval vessels, attack helicopters, etc which are noted on the USML with an asterisk.  Some examples include; an export license (DSP-5), exchanging technical emails or teaching how to repair an ITAR-covered item which requires a Technical Assistance Agreement (TAA), and allowing a foreign company to manufacture an item requires a Manufacturing License Agreement (MLA).

 

EAR:

Most other items not specifically listed in the USML, but with the capability to be used for either civilian or military purposes are considered “dual-use” and controlled under the Export Administration Regulations (EAR) which is administered by the Bureau of Industry and Security (BIS) at the Department of Commerce (DoC).   The Commerce Control List (CCL) is the equivalent list at the DoC to the State Department’s USML.  The CCL specifically controls for Chemical & Biological Weapons, Nuclear Nonproliferation, National Security, Missile Technology, Regional Stability, Firearm Convention, Crime Control, and Anti-Terrorism.  The level of control depends on the country being exported to, destination party, end-use, and Export Control Classification Number (ECCN).  Specifically, there are “600 Series” and “500 Series” items that are more strictly controlled than the rest of the CCL, but less strictly controlled than the articles on the USML.

Who should attend?

This introductory course is for business executives, international contracting specialists, contract managers and administrators, program and project managers, marketing professionals, engineers, and other technical personnel, newly appointed export compliance officers, logistics personnel, and legal and financial advisors.

Why go to this class?

  1. ITAR isn’t easy-you will need a guide to help you through
  2. Online courses require no travel
  3. This 1-day training is only on our calendar six times a year.
  4. Everything your company manufactures or offers services on is either subject to the ITAR or EAR Regulations.
  5. Failure to comply with ITAR can result in civil fines are as high as $500,000 per violation, while criminal penalities include fines of up to $1,000,000 and 10 years imprisonment per violation.

 

Counterfeit Parts AS5553 Class

We teach you how to identify and prevent the use of counterfeit parts

Days: 1 • CEU Hrs: 4.8
Time: 7:30 a.m.- 4:30 p.m. MST
Audience: Beginner to Advanced

Overview

  1. Discuss Industry Problems with Counterfeit Parts and industry efforts on Counterfeit Part Prevention
  2. Discuss Industry Efforts On Counterfeit Part Prevention
  3. Discuss Role of G-19, AS5553 and Other Standards
  4. Discuss the Roles of Various Groups within an Organization in Preventing Counterfeit Parts from Entering Product
  5. Discuss Methods for Auditing Counterfeit Parts Prevention (CPP) within AS 9100C/AS 9120B (ISO 9001:2015)
  6. Internal Audits

Who Should Attend?

  • End User (government or commercial using platforms, systems, and/or equipment e.g. UK MoD, US DoD, NASA etc.)
  • Platform Integrator
  • Systems Integrator
  • OEM (System level e.g. Radar, Lower Level e.g. Power Supply)
  • CEM (Board Level)
  • Product Maintenance/Repair Organization
  • Material Procurement Organizations (e.g. BPO organizations etc.)
  • Others (any organization contracted by a customer to comply or who chooses to use to enhance its processes)

Agenda

  • The training of personnel
  • The inspection and testing of electronic parts
  • Processes to abolish counterfeit parts proliferation
  • Processes for maintaining electronic part traceability
  • Use of suppliers that are the original manufacturer, or {authorized dealer}
  • Reporting and quarantining
  • Methodologies to identify suspect counterfeit
  • Design, operation, and maintenance of systems
  • Flow down of counterfeit detection and avoidance requirements
  • Process for keeping continually informed of current counterfeiting information and trends
  • Process for screening GIDEP reports and other credible sources
  • Control of obsolete electronic parts

 

AS9102 First Article Inspection

Days: 1 • CEU Hrs: 0.8

Time: 7:30 AM- 4:30 PM MST

Audience: Beginner to Advanced

Overview

The aviation, space, and defense industry established the International Aerospace Quality Group (IAQG).  The IAQG strives to improve quality and safety while reducing cost throughout the value stream. The AS9102 First Article Inspection standard applies to the complete value stream.

The FAI process requirements are used at all levels of the supply chain by organizations around the world.  This standard provides a consistent process and documentation requirements for verification of aviation, space, and defense product.

Its use should result in improved: a) quality, b) schedule, and c) cost performance by: the reduction or elimination of organization-unique requirements and wider application of good practices.

Prerequisites

There are no required prerequisites.  This course is routinely taught to quality novices and life-time professionals. All attendees are required to bring their own copy of the AS9120. These will not be provided for you. We strongly advise you bring a “paper” copy.

Course Objectives

  • Prepared to conduct a solo internal audit at successful course completion
  • Fully understand and interpret the AS9100:2016 Rev D requirements.
  • Apply the proper interpretation of the standard in actual audit situations.
  • Understand process auditing tools leading to substantive quality system improvements
  • Tailor an audit interview based on the requirements of the standard and obtain audit evidence from this interview.
  • Follow-up and resolve “audit trails that present themselves during the audit interviews
  • Conduct audits that result in real improvements to the quality system
  • Plan and execute the entire audit process including: audit preparation, opening meetings, auditing, closing meetings, and reporting

Agenda

  1. Introduction to: the Course Objectives and the Purpose, Intent and Proper Application of First Article Inspection
    • Why do we use the FAI process?
    • When is AS9102 required? When is AS9102 not required?
    • What is required by AS9100 (an AQMS)?
    • What are practical tools for Process and Process change control in addition to/in lieu of FAI:
      • Risk Assessment
      • Production Capacity
      • Process Capability
      • Control Plan
      • Supplier Control
  2. The IAQG and Standards Development
  3. AS9102 Terminology
    • Terminology Game and Understanding the Forms lingo
  4. Comprehensive Review of the AS9102 rev B Requirements and How to Complete the FAIR per Appendix B
    • The Required (R), Conditionally Required (CR) and Optional (O) boxes
    • Forms Review and Detailed Requirements for each Form and Box
  5. Understanding the Reporting and Objective Evidence Required in the FAIR (Firsts Article Inspection Report)
    • In-Class evaluation of Examples of Completed AS9102 Forms 1, 2 and 3
    • The Planning, Activities and Documentation necessary to complete the AS9102 Forms
  6. Good Practices for Completing and Reviewing FAIRs
    • In-Class Exercise of Evaluating Drawings and Documenting the FAI Objective Evidence
    • In-Class Exercise Reviewing Completed FAIRs
  7. Completing the AS9102 Forms from Source Documents. How to divine the necessary information and proper presentation of information in Forms: 1, 2 and 3
    • Case Study: Using Drawing, Certificates of Conformance, Bill of Materials to Complete a full FAI Report
    • Case Study: Missing information and sources of Objective Evidence for the FAI Report
  8. FAIR Checklist Items for Reviewing and Approving Organization and Supplier FAIRs

AS9100 Overview

 

This course is designed for managers and executives that need to understand the requirements of AS9100 and the implications for their organizations.

Learn what AS9100 registration means for your organization and how to implement it to your AS9100 Rev D QMS to gain a competitive advantage.

Many organizations are introduced to management systems because they are forced to consider ISO certification.  This overview shows how system development can happen in many different ways, but the best approach is to investigate your existing processes and system and align them with your business objectives.

As leaders, Top Managers need to be stakeholders in the achievement of the Quality Management System, accountable for its effectiveness and engage the company in achieving the intended results of the QMS – among other requirements. Every organization is different, so we customize every executive overview to incorporate top management’s particular learning and system development objectives.

Who should attend?

  • Top Managers
  • Quality professionals
  • VP/Directors of Quality
  • ISO Managers/Management Reps
  • Process owners
  • Systems professionals
  • Improvement Specialists

You will learn:

  • What does the quality system mean to you as manager, and to your team?
  • AS9100 leadership requirements per clause 5 and connecting it to other clauses in the standard
  • AS9100 and the Risk Based Approach to implementing management systems
  • The Quality principles per AS9100 and the changes to them
  • How systems work
  • Leadership requirements for developing the management system
  • Leadership requirements for running and continually improving the management system
  • The main changes to the standard including:
    • Aligning it to the High Level Structure
    • Change in terminology
    • Change in structure