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Seller shall comply with the following requirements
and flow down all applicable sections to its subcontractors:
1.0 At least annually, the Seller
shall conduct an internal audit to ensure compliance
to their quality system and the controlling quality
assurance document.
1.1 Seller shall promptly notify
Boeing of any changes in the management representative
with assigned responsibility and authority for
the quality system.
1.2 Seller shall immediately notify
Boeing, in writing, of any change to the manufacturing
facility location for the contracted part or assembly.
1.3 Seller shall immediately notify
Boeing, in writing, of any change to the Seller's
quality manual (or top level document) that may
affect continued compliance to Document D6-82479,
"Boeing Quality Management System Requirements
for Suppliers". After the issue of initial
Boeing quality system approval, each change to
the quality control system is subject to review
by Boeing.
1.4 Unless otherwise specified, all
Supplier notifications to the Boeing Company,
described above, shall be communicated, in writing,
to the Boeing Procurement Agent and the Primary
Boeing Procurement Quality Representative.
1.5 When specifically requested by
Boeing, Seller shall make specified quality data
and/or approved design data available in the English
language.
Seller shall maintain an English language translation
of (1) its quality manual and (2) an index of
all other Seller procedures that contain quality
requirements. Boeing may require the Seller to
translate additional documentation.
1.6 Digital Product Definition: Boeing
document D6-51991, "Quality Assurance Standard
for Digital Product Definition at Boeing Suppliers".
When Type Design Digital Product Definition (DPD)
data is utilized in manufacturing, inspection
and sub-tier flow-down of product definition,
Seller shall have a quality system to control
Type Design DPD data to the extent necessary to
fulfill program requirements. Seller must obtain
Boeing DPD capability approval.
1.7 The disposition "re-grade"
shall not be used on products of Boeing proprietary
design.
1.8 Retention of Records. For orders
supporting BCA, Seller shall maintain, on file
at the Seller's facility, Quality records traceable
to the conformance of product/part numbers delivered
to Boeing. Seller shall make such records available
to regulatory authorities and Boeing's authorized
representatives. Seller shall retain such records
for a period of not less than (7) seven years
from the date of shipment under each applicable
order for all product/part numbers unless otherwise
specified on the order.
At the expiration of such period, Boeing reserves
the right to request delivery of such records.
In the event Boeing chooses to exercise this right,
Seller shall promptly deliver such records to
Boeing at no additional cost on media agreed to
by both parties.
1.9 Seller shall strictly control
all inventory of Boeing proprietary product that
is in excess of contract quantity to prevent product
from being sold or provided to any third party
without prior written authorization from Boeing.
1.10 When Boeing notifies the Seller
of a detected nonconformance, the Seller shall
immediately take action to eliminate the nonconformance
on all products in Seller's control. Seller shall
also maintain, on file, verification that root
cause corrective action has occurred and has resolved
the subject condition. At the specific request
of Boeing, this verification shall occur for the
next five (5) shipments after implementation of
the corrective action to ensure detected nonconformance
has been eliminated. Boeing reserves the right
to review the verification data at the Seller's
facility or have the data submitted to Boeing.
1.11 Where Seller is requested to
submit a corrective action report, Seller will
submit its response within ten (10) days of receipt
of such request unless an extension is otherwise
provided by Boeing. Any corrective action report
submitted to Boeing shall be in the format specified
by Boeing. If after submittal to Boeing, Seller
determines need for revision, Seller shall immediately
notify Boeing of such revisionIn the event Seller
is unable to respond within the allotted ten day
time frame. Seller shall submit a request for
extension which shall include the reason for the
extension request and the time needed to complete
the corrective action report.
Seller shall provide written notification to
Boeing within one business day when a nonconformance
is determined to exist, or is suspected to exist,
on product already delivered to Boeing under this
purchase document when any of the following is
known:
- Affected process or product number and nomenclature;
- Description of the problem (i.e., what it
is and what it should be);
- Quantity and dates delivered;
- Suspect/affected serial number(s) or date
codes, when applicable.
Notification shall include the above information
as a minimum. The Seller shall notify the Boeing
Procurement Representative who manages the purchase
contract, the Boeing Procurement Quality Assurance
Field Representative, the Boeing Procurement Quality
Assurance organization where product was procured
and the supporting Boeing Procurement Quality
Assurance organization where the product was delivered.
1.12 The Seller shall be responsible
for achieving and maintaining a quality performance
level of either:
- Supplier Performance Measuring System (SPMS)
site quality acceptance rate, of 98% as calculated
by taking the ratio of acceptable units delivered
to the total units delivered for the prior 12
month period. This calculation may be based
on a composite quality performance score from
all contracts/purchase orders between the Seller
and the Boeing contracting site, or specific
by program to which this agreement applies or;
- Equivalent alternate criteria quality performance
rating as defined by the site(s) when the standard
SPMS calculation does not accurately reflect
the Seller's quality performance.
1.13 If Seller fails to achieve and
maintain 98% site quality acceptance rate, which
is a prerequisite for delegated inspection authority
awarded at Boeing's discretion, the Seller shall
be responsible for one or more of the following
as directed by Boeing:
- Obtaining source inspection from a Boeing-qualified
contractor at Seller's own expense;
- Reimbursing Boeing for reasonable Boeing costs
incurred at the point of manufacture (i.e. Seller's
site) to verify product conformance;
- Reimburse Boeing for reasonable Boeing costs
incurred at the point of receipt to verify product
conformance.
1.14. Boeing recognition of Seller's
Aerospace Quality Management System (AQMS) certification/registration
does not affect the right of Boeing to conduct
audits and issue findings at the Seller's facility.
Boeing also reserves the right to provide Boeing-identified
quality system findings, associated quality system
data, and quality performance data to the Seller's
Certification/Registration Body (CRB).
1.15. Seller shall ensure the following
relative to AQMS certification:
1.15.1 The certification/registration
body CRB is accredited to perform AQMS assessments.
The CRB must use approved auditors and operate
in accordance with the corresponding International
Aerospace Quality Group (IAQG) certification/registration
scheme.
NOTE: IAQG sanctioned certification/registration
schemes include, but are not limited to AIR 5359,
SJAC 9010, TS157, etc. Reference IAQG web-site
for listing of accredited CRBs http://www.iaqg.sae.org/servlets/index?PORTAL
1.15.2 The Seller
maintains objective evidence of CRB certification/registration
on file at Seller's facility. Objective evidence
shall include:
- The accredited AQMS certificate(s) of registration;
- The audit report(s), including all information
pertaining to the audit results in accordance
with the applicable certification/registration
scheme;
- Copies of all CRB finding(s), objective
evidence of acceptance of corrective action(s),
and closure of the finding(s);
Certification records shall be maintained in
accordance with Boeing specified contractual quality
record retention requirements.
1.15.3. The CRB
services agreement provides for "right of
access" to all CRB records by Boeing, applicable
accreditation body, applicable Registrar Management
Committee (RMC), and other regulatory or governmental
bodies for the purpose of verifying CRB certification/registration
criteria and methods are in accordance with the
applicable IAQG certification/registration scheme.
1.15.4. The CRB
has the Seller's written permission to provide
audit results/data to IAQG membership as required
by the applicable IAQG certification/registration
scheme.
1.15.5. Boeing
is immediately notified, in writing, should the
Seller's certification/registration be suspended
or withdrawn, or accreditation status of the Seller's
CRB be withdrawn. Send email notification to:
grpcrborversightrep@boeing.com
1.15.6. Boeing-identified
findings and Seller's quality performance data
is provided to the CRB during certification/registration
and surveillance activity.
1.15.7. CRB shall
be provided access to applicable proprietary data
(including Boeing proprietary data) to the extent
necessary to assess Seller's compliance to AQMS
requirements. CRB shall agree to keep confidential
and protect Boeing proprietary information under
terms no less stringent than Seller's contractual
agreement with Boeing. Seller will assure that
such information is conspicuously marked "BOEING
PROPRIETARY".
1.15.8. Seller
complies with all CRB requirements imposed to
issue and maintain certification/registration.
1.16 Seller and their subcontractor(s)
shall utilize sources listed in Document D1-4426
"Approved Process Sources" whenever
the manufacturing and/or inspection processes
listed in D1-4426 are performed on this purchase
document. The current version of D1-4426 is accessible
via the internet at the following web address
http://www.boeingsuppliers.com/d14426/
1.17 Seller shall maintain actual
processor certification for all D1-4426 special
processes performed in accordance with the requirements
of this purchase document. In addition to all
certification requirements defined by the applicable
processing specification(s), the certifications
shall contain the following:
- The complete part number of the article(s)
represented by the certification;
- The total quantity of the parts (for each
part number) represented by the certification;
- The company name and address of the performing
processor. The address shall include street
address, city and state;
- The specification number(s) and revision letter
of the D1-4426 process performed.
Seller shall provide such certification upon
Boeing request.
1.18 Seller shall provide their sub-tier
process sources with the prime site of the Boeing
Company (that is the design authority) as well
as the aircraft model number or hardware that
the part numbers represent when applicable.
1.19 Seller's use of approved processors
does not relieve Seller from verifying that the
processor and the products conforms to all applicable
process specification requirements.
1.20. Where Boeing specifications
and/or processes are listed within the detail
design, specification control, or envelope drawing,
incorporated by this purchase document, Seller
shall adhere to the latest revision of the Boeing
specification and/or process, unless otherwise
specified in the purchase document.
1.21. Shipping Documentation:
1.21.1 The Seller's
shipping documentation shall contain the following:
- A Packing Sheet;
- A Certification of Compliance Statement
(may be included as part of the packing sheet);
- Evidence of Seller's Product Acceptance;
- A copy of any NCR/rejection tags for the
articles shipped, as applicable;
- A copy of any completed Boeing corrective
action request follow-up documentation for
article(s) being shipped;
- Evidence of Boeing's product acceptance,
when Boeing Source Acceptance is required;
- A Serialized Parts List identifying parts
with an assigned serial numbers. The list
shall contain the part numbers, part nomenclature
and part serial numbers. This list shall also
include part change letters when applicable;
- The NCR/rejection tag number(s) as applicable;
- Control identity of the end item deliverable
of raw material or purchased articles, as
applicable. The control identification is
traceable to the product processed in a single
run (same manufacturing date, lot, batch,
heat, job or shop traveler number). When multiple
lots are included in one shipment, Seller
shall clearly separate the control identity
of the respective lots.
1.21.2. In addition
to the requirements of 1.13.1 Sellers furnishing
Long Beach product shall include the following
with the shipping documentation when applicable:
- A copy of the approved Manufacturing Implementation
Plan (MIP) with all required signatures;
- The original LBD-issued Work Order Form
DAC 26-114B, when used as a releasing document
communicating quality requirements;
- Interface Control Drawing (ICD) and/or
Variability Data (VR) data when an ICD plan
is a contractual requirement.
When the procurement document invokes Source
Acceptance or Inspection Delegation, D1-4426 Certifications
are not required as part of the shipping documentation.
1.21.3. In addition
to the requirements of 1.13.1 Sellers furnishing
Puget Sound product shall ensure that exterior
shipping documentation is enclosed in a yellow
envelope to facilitate processing upon receipt
at Boeing.
1.21.4. In addition
to the requirements of 1.13.1, Sellers furnishing
Tulsa product shall include the following with
the shipping documentation:
- Seller's shipping documentation shall include
a complete copy of the Seller's First Article
Inspection Report when the procurement involves
"First Articles".
- Certification listing all articles which
must be procured from Boeing Qualified Manufacturer.
Certifications must contain the following
information:
- The article specification, drawing or
standard and revision;
- Name and complete address of the Boeing
Qualified Manufacturer;
- Name of the Manufacturer's Authorized
Distributor for D590 standards when the
purchase document is not placed with the
manufacturer;
- Evidence of as built engineering configuration
and planning configuration (SPRAT).
- The material certification(s).
- When the procurement document invokes Source
Acceptance or Inspection Delegation, D1-4426
Certifications are not required as part of
the shipping documentation.
1.21.5. In addition
to the requirements of 1.13.1, Sellers furnishing
Wichita product shall include the following with
the shipping documentation.
- Certification listing all articles which
must be procured from Boeing Qualified Manufacturer.
Certifications must contain the following
information:
- The article specification, drawing or
standard and revision;
- Name and complete address of the Boeing
Qualified Manufacturer;
- Name of the Manufacturer's Authorized
Distributor for D590 standards when the
purchase document is not placed with the
manufacturer;
- All D1-4426 Certified Special Process (CSP)
certifications, as applicable;
- The material certification(s).
- The CAR number(s).
1.22 The Seller shall notify Boeing,
in writing, of any subcontractors who meet the
following criteria:
- The Seller makes a determination of product
conformance by means other than source inspection;
- The Seller or their subcontractor(s) delegate
inspection authority to their subcontractors;
- The subcontractor ships product directly
to Boeing;
- The subcontractor is performing processes
requiring Boeing approval.
1.23. The Subcontractor Notification
shall include subcontractor name, address, telephone
number, QA manager's name, applicable product
numbers, product descriptions, applicable Boeing
approvals and special processes.
1.24 The Seller shall immediately
notify Boeing (within one business day) in writing
when a nonconformance is determined to exist,
or is suspected to exist, on product already delivered
to Boeing under this agreement. Notification shall
include the following information as a minimum:
- Affected process or product number and name;
- Applicable purchase order number(s), quantity,
and dates delivered;
- Description of the problem (i.e., what it
is and what it should be);
- Affected drawing number(s) and zone(s);
- Suspect/affected serial number(s) or date
codes, when applicable;
- Proposed actions/requests (i.e., units to
be checked, recording required, method of check,
etc.).
The Seller shall notify the Boeing Procurement
Representative who manages the purchase contract,
the Boeing Procurement Quality Assurance Field
Representative, and the Boeing Procurement Quality
organization where product was delivered. For
product procured by BCA Puget Sound, the Seller
shall also notify BCA Supply Management and Procurement
Special Investigations Group via e-mail at (smpsi@boeing.com)
or by fax at (425-294-2160).
1.25. Boeing reserves the right to
reject any root cause and/or corrective action
determination provided by the Seller, and may
request subsequent investigation and/or corrective
action to either Boeing or Seller-initiated corrective
action requests. If the Seller is late in responding
to Boeing corrective action requests, or if Boeing
requires subsequent corrective action, Boeing
reserves the right to withhold acceptance of shipments
either at source or destination until Seller corrective
action is submitted to Boeing's satisfaction.
1.26. Retention of Records. For orders
supporting BCA, Seller shall maintain, on file
at the Seller's facility, Quality records traceable
to the conformance of product/part numbers delivered
to Boeing. Seller shall make such records available
to regulatory authorities and Boeing's authorized
representatives. Seller shall retain such records
for a period of not less than (7) seven years
from the date of shipment under each applicable
order for all product/part numbers unless otherwise
specified on the order.
At the expiration of such period, Boeing reserves
the right to request delivery of such records.
In the event Boeing chooses to exercise this right,
Seller shall promptly deliver such records to
Boeing at no additional cost on media agreed to
by both parties.
1.27. Digital Product Definition:
Boeing document D6-51991, "Quality Assurance
Standard for Digital Product Definition at Boeing
Suppliers". When Type Design Digital Product
Definition (DPD) data is utilized in manufacturing,
inspection and sub-tier flow-down of product definition,
Seller shall have a quality system to control
Type Design DPD data to the extent necessary to
fulfill program requirements. Seller must obtain
Boeing DPD capability approval.
1.28. Seller Developed Digital Product
Definition (SDPD):
- Seller electing to develop digital manufacturing
processes from two dimensional (2D) engineering
provided by LBD shall obtain written approval
from the LBD Program Office and LBD Supplier
Quality prior to changing the currently approved
process.
- The Seller shall develop a Quality System
to verify digital controlled processes are traceable
to the LBD approved type design. Seller shall
treat all SDPD for LBD product as derivative
data-sets and protect the SDPD as Boeing type
design. The Seller shall demonstrate configuration
management to ensure engineering revisions are
incorporated at the proper effectivity.
- Seller shall not modify tooling-controlled
processes using SDPD when LBD Master tooling
has been developed as the source data for the
tooling; unless LBD Tool design has developed
a DPD Master Graphics Model to replace hard
Master tooling. LBD Tooling Inspection must
validate tooling reconfigurations necessitated
by the development of digital definition per
Section 3.0 below.
- The Seller shall develop and provide LBD
Supplier Quality with a comprehensive plan describing
the Seller's quality system for management of
Seller developed digital data and SDPD processes
throughout its production facilities. The requirements,
procedures and process references described
in the plan shall provide the basis for Seller
organizations to implement user-level procedures
and documentation.
- The Seller shall provide inspection plans
for all product(s) and tooling manufactured
using digital definition. LBD Tooling Inspection
must approve Seller's digital definition for
inspection media unless delegated in accordance
with Section 3.0 below.
- The Seller shall develop and maintain procedures
to ensure identification and the configuration
of SDPD controlled production hardware, tooling
and the following SDPD systems:
- Seller developed Product Acceptance Software(PAS)
- Computerized Measurement Systems (CMS)
- CAD/CAM software and data-sets
- Seller Data Analysis Software
- Seller generated datasets (derivative
datasets)
- Seller Inspection datasets
- Datasets flowed to subcontractors
1.29. The Seller shall immediately
notify Boeing in writing of any change to the
quality control system that may affect the inspection,
conformity or airworthiness of the Product. After
the issue on initial Boeing quality system approval,
each change to the quality control system is subject
to review by Boeing.
2.0. Seller shall not contract with subcontractors
located outside the United States or its possessions
who meet the aforementioned Subcontractor Control
criteria without written acceptance by LBD. Seller
shall furnish the information required by Paragraph
1.4 above upon LBD request.
3.0. LBD/Seller Tooling Used to Manufacture LBD
Product
3.1. The Seller shall comply with
the below noted instructions in lieu of D33200.
These instructions apply to Sellers fabricating,
performing rework, repair, or modifications to
airframe and structure component type tooling
for LBD product. Sellers' electing to use Electronic
datasets to define Seller tooling used to control
Boeing product must communicate such intent, Seller
will be evaluated on the type of equipment used
to establish such controls. Computerized Measurement
Systems (CMS), used by a Seller must be certified
to the accuracy required to meet Tool Design tolerances.
3.2. The Seller shall utilize the
following tool categories:
- Category I Tooling includes the following:
Seller or LBD Master tooling, interface control
tooling, master control tooling, master models,
master graphics models, master gauges, master
templates, two dimensional (2D) and/or three
dimensional (3D) electronic models and all other
tooling establishing or controlling the tool
definition.
- Category II Tooling includes the following:
Interchangeability and Replaceability (I&R)
tooling, production end-item inspection tooling,
check fixtures, inspection gauges, major structure
assembly jigs and sub-assembly jigs for end
item assemblies (when characteristics cannot
be validated in the end item assembly tool),
and or I & R assemblies.
- Category III Tooling includes, but is not
limited to the following:
Hammer dies, blanking tools, hydro blocks, stretch
form blocks, post form blocks, router boards,
spin blocks, non inspection media trim templates,
and drill bars.
3.3. The Seller and their subcontractors
shall inspect tools under contract with LBD and
shall establish and maintain a documented system
for the control, accountability and configuration
management of tooling to LBD Engineering Type
Design and Quality requirements.
3.4. The Seller and their subcontractors
must be approved by LBD Supplier Quality Tooling
prior to design and/or fabrication of Category
I and Category II tooling used for LBD product.
3.5. The Seller shall contact the
LBD Procurement Agent and request a Tooling Systems
Survey when conducting tooling work for LBD product.
3.6. All "Category I" and
"Category II" tooling fabricated, reworked
or repaired by the Seller must have a Seller and
LBD Supplier Quality Tooling stamp on the documentation
and tool prior to use, except flat pattern tooling
fabricated from LBD Supplier Quality Tooling-approved
Master Lay-Out (MLO), LBD-furnished MLO/Computer
Produced Vellum Overlay (CPVO), or LBD-furnished
Un-Dimensioned Drawings (UDDs).
3.7. All "Category I" tooling
fabrication/rework/repair requires communication
with LBD Supplier Quality Tooling prior to starting
work to enable acceptance planning by LBD Supplier
Quality Tooling.
3.8. When the Seller detects damage
or deviation to any Category I tool, the Seller
must report the information to LBD Supplier Quality
Tooling. On Category II Tooling, the Seller shall
maintain a record of all deviations found with
corrective actions coordinated and approved by
LBD Supplier Quality Tooling and provided to LBD
upon request.
3.9. The Seller shall not modify,
rework, or repair any LBD tooling without prior
LBD Supplier Quality Tooling approval.
3.10. Verification that an article
conforms to blueprint requirements made from a
tool used as a Media of Inspection (MOI) does
not constitute acceptance verification of Category
I & Category II tooling.
3.11. Master Tools (Category I).
- The prime responsibility for the creation,
accountability, control, and maintenance of
Master tools is vested in LBD.
- Master tools shall not be reworked, repaired,
modified, duplicated, or have any part deleted
without specific written approval of LBD Supplier
Quality Tooling.
- A Tool Design is required for every Master
Tool and all gauges set to Masters in the possession
of a Seller.
- The Seller shall verify and record the Master
reference system dimensions prior to cycling
Master in any assembly tooling.
- Master Tooling shall not be used to directly
produce LBD product.
- Master Tooling Designs shall include the
proper storage container for the Master Tool.
The Seller shall ensure the Master Tools are
stored to prevent distortion, corrosion or weather
damage.
3.12. When the Seller elects to convert
physical Master tooling to Electronic Definition
the Seller shall follow this preferred process
for gage elimination and replacement with digital
configuration control. Digital configuration will
replace the use of physical Category I Tooling
as a Manufacturing control Media. Digital configuration
will also be used to perform periodic tool inspection
(routine check) of manufacturing production tooling,
replacing the use of Master Models and Physical
Gauges.
- Seller must have a Boeing approved CAD/CAI
CMS capability
- Tooling must be physically capable of conversion
to and applying CMS digital control.
- The business case must support conversion
effort.
- The Seller must request to Boeing via a Gaugeless
Tooling Conversion Request Form.
3.13. Opening and Closing of LBD
provided Master Tooling containers. The Seller
shall contact LBD Quality Assurance for verification
of Master Tooling condition prior to the opening
and/or closing of LBD provided Master Tooling
containers. The Seller shall notify LBD Supplier
Quality Tooling in the event of any damage to
the Master Tooling container.
3.14. Seller Tool Inspection.
- Seller and subcontractor tooling shall be
inspected by the Seller prior to first usage.
Quantitative inspection results shall be recorded
on a format approved by LBD Supplier Quality
Tooling.
- All MOI tooling and any other tooling identified
by LBD Quality Assurance or the Seller shall
undergo periodic inspection by the Seller to
verify continued conformance of the tool.
- Initial Periodic checks shall be witnessed
and concurred with by LBD Supplier Quality Tooling
for all new, relocated, reactivated, or converted
Category II tools. The Seller shall notify LBD
Supplier Quality Tooling when an initial periodic
inspection will occur. Initial periodic check
data shall be recorded at tool set-up and after
each assembly built in the tool for a minimum
of three (3) assemblies to prove tool stability
and establish Periodic frequencies. Periodic
inspections shall not be delayed due to absence
of LBD Supplier Quality Tooling. Records of
periodic inspections will be made as part of
the Tool history data maintained by the Seller,
and shall be made available for review during
LBD Supplier Quality Tooling System Survey activities.
- New, relocated, reactivated, or converted
Category I and II tools require acceptance by
LBD Supplier Quality Tooling. Acceptance of
Category III tools is the responsibility of
the Seller. Category III tools shall be subject
to acceptance by LBD Quality Assurance.
- The Seller shall notify LBD Supplier Quality
Tooling, of intent to use Electronic Digital
Data to validate any Category I and II tooling,
and any other tooling when used to control an
Interchangeable Part or Assembly. LBD Tooling
will evaluate the Seller's capability to implement
and control digital inspection datasets.
3.15. Notification of LBD Supplier
Quality Tooling: The Seller shall provide LBD
Supplier Quality Tooling sufficient notification
to complete required tool acceptance, per the
following lead times specific to the Seller's
location:
- Local (7 Southern California counties) -
Forty-eight (48) hours
- North America (Continental United States,
Alaska, Mexico) - Ten (10) Working Days
- International (including Hawaii) - Thirty
(30) Working Days
The Seller shall have all tooling
inspection documentation completed for in-process
(progressive) and final inspection prior to the
arrival of LBD Supplier Quality Tooling.
3.16. Seller Mylars
- All new or modified, Seller Mylars, including
those created from electronic data, shall be
validated by the Seller and accepted by LBD
Supplier Quality Tooling.
- Reproduced Seller Mylars must be full size
and include the LBD acceptance stamps. Reproduced
Mylars do not require reacceptance by LBD Quality
Assurance. When reproduced, the original Seller
Mylar shall be maintained by the Seller as the
Master. Reproduced Seller Mylars shall be checked
for dimensional accuracy by measuring the ten
(10) inch grid line, or valued targets on the
Mylars. The Seller shall have a documented process
for reproduction and control of any Mylar.
3.17. Reserved
3.18. Delegation: The Seller may
be delegated to perform Tooling Inspection processes
by LBD Supplier Quality Tooling. Specific instructions
will be communicated to the Seller in writing
noting delegated processes or partial processes
applicable to the Seller's activity. Delegated
authority shall not be transferred by the Seller,
to subcontractors.
3.19. Interchangeability: The Seller
shall conduct Interchangeability demonstrations
when identified on design data. The Seller shall
conduct demonstrations on the first production
article with subsequent demonstrations conducted
until the quality history justifies skip-lot inspections.
Interchangeability demonstrations may be accomplished
by any one of the following methods:
- Two or more items selected at random and
installed on the next assembly or end item
- One item selected at random and installed
on two or more next assemblies or end items;
- One item checked in a certified tool and
then installed on a next assembly or end item
without alteration;
- Two or more items installed in a certified
tool
3.20. Verification of Fabrication
Category III Tooling is normally the responsibility
of the Seller, However; when conditions of assembly
warrants investigation, LBD Supplier Quality Tooling
will evaluate such tooling to support in the elimination
of manufacturing issues. This may also include
the activities performed at Seller's Subcontractors.
4.0. Control of Nonconforming Product
4.1. Product nonconformance documentation
forms shall, at a minimum, provide:
- a clear identification of the part;
- a space for disposition and authorized signature;
- a complete description of the condition including
"is" and "should be";
- a statement of the cause;
- the corrective action taken.
The Seller shall make all MRB tags
for product which will undergo FAA certification
testing or FAA Conformity available to LBD.
4.2 Repetitive Nonconformances: Seller
shall implement corrective action on repetitive
nonconformances dispositioned as "use-as-is"
to preclude changes to type design being made
through MRB action rather than through the Seller's
change system.
4.3. If a nonconforming part, which
has been accepted or repaired in accordance with
Seller or LBD Material Review Board disposition,
is evident in the end-item ordered by LBD, the
Seller shall identify the shipment as such and
shall retain copies of the specific Material Review
Board documentation. Seller shall furnish said
documentation upon LBD request.
4.4. LBD Notification of Rejection:
When product is rejected by LBD, and the cause
of the rejection has been determined to be the
Seller's fault, the Seller will be provided a
copy of the LBD Failure and Rejection Report (FRR)
(Form DAC 37-104) The Seller shall, when requested,
provide an acceptable corrective action response
within a specified time frame.
4.5. Inspection of Previously Identified
Defects: When nonconformances in Seller's product
are discovered at LBD, the Seller shall inspect
the next five (5) deliveries (as a minimum) of
similar product to LBD and may be requested to
include as part of the shipping documentation
objective evidence of inspection of the next five
(5) deliveries (as a minimum) of similar product
to LBD. LBD shall have the right to reject such
product without objective data (i.e., test data,
certifications, etc.) identifying that appropriate
inspections have been accomplished to verify the
nonexistence of the nonconforming condition, which
was brought to the Seller's attention by LBD.
4.6. When LBD identifies nonconforming
product and determines the cause to be the Seller's
fault, LBD will provide the Seller with notification
in the form of a Nonconformance Notification (NN)
or Supplier Corrective Action Notice (SCAN). Upon
receipt of such notification, the Seller shall
develop and implement acceptable corrective action.
When a SCAN is used for notification, the Seller
shall comply with the requirements of SCAN Attachment
1.
When the Seller disagrees with the
determination of fault, Seller shall submit a
written request for a Change of Charge (COC) to
the initiator within thirty (30) calendar days
from the date of notification. The request must
include the reason and documentation/objective
evidence supporting the request. Failure to notify
LBD of disagreement with the determination of
fault will be deemed to be a confirmation of the
Seller's acceptance of nonconformance responsibility.
5.0. Material Review:
5.1. LBD Right of Review and Disapproval:
LBD reserves the right to disapprove the Seller's
disposition of nonconforming product and to require
subsequent corrective action at any time.
5.2. Requests for LBD Material Review
Board Authority: When the Seller applies for Material
Review Board (MRB) authority, the Seller shall
coordinate requests for approval or revision in
writing with the LBD Principle Member of MRB (PM-MRB)
through the LBD Procurement Agent. Unless provided
written authorization by LBD, the Seller or their
subcontractors are not delegated MRB Authority
for LBD-designed articles and shall not function
as such until they receive written authorization
from LBD. The LBD PM-MRB is the sole authority
for delegating LBD MRB authority. The Seller's
MRB shall consist of approved representatives
from Quality and Engineering. D-13709-4, Requirements
for Obtaining Materials Review Board (MRB) Authority
by Boeing Suppliers, does not apply to LBD product.
5.3. Seller MRB Disposition Requirements
and Limitations.
- The Seller shall not disposition any product
pursuant to this Purchase Document line item
as "regrade".
- Any nonconformance of the Seller's own detailed
design, manufacturing, or process requirements
not included in, or affecting specifications
or drawings forming a part of this purchase
document may be handled by the Seller's normal
material review process. The Seller shall not
make repairs or accept, without repair any nonconforming
condition adversely affecting fit, form, function,
performance, safety, weight, maintainability,
service life, interchangeability, appearance
(where a factor) for this Purchase Document
line item.
- MRB dispositions, in which (1) the modification
is extensive, (2) load paths are modified, or
(3) fatigue life or ultimate strength are affected,
shall be substantiated by a stress analysis
documented in a Technical Journal (TJ). Seller
Structural Mechanics Engineers may be authorized
to prepare TJs by LBD Structural Mechanics Engineering
and the LBD PM-MRB. Such delegation is initiated
by submitting a request to the PM-MRB through
the LBD Purchasing Representative.
- Seller authorized to perform Engineering
MRB actions by the PM-MRB is required to coordinate
with the LBD Engineering MRB group all MRB actions
which may affect a LBD interface, or those actions
which may adversely affect fit, form, function,
performance, safety, weight, maintainability,
service life, interchangeability, appearance
(where a factor), or customer acceptance.
- LBD Quality Assurance may require MRB actions
to be coordinated with LBD Liaison Engineering
at any time.
- MRB dispositions provided by a delegated
Seller MRB engineer (or with concurrence of
a LBD MRB engineer to "USE AS IS"
or "REPAIR" a non-conforming product
is a conditional acceptance of the product and
can be rejected by LBD at any time due to LBD
or customer dissatisfaction with the MRB dispositioned
material, product. MRB dispositions do not relieve
the Seller of any financial, performance, or
other contractual responsibility in the event
the customer is dissatisfied with the product.
5.4. Rework/Repair SEOs and CSEOs.
- Serial Engineering Orders (SEOs) and Coordinated
Serial Engineering Orders (CSEOs) are prepared
per the requirements in the LBD Drafting Manual.
Proposed rework/repair SEOs shall be coordinated
with the LBD Engineering MRB group and advance
released by the Seller following specific written
approval by the LBD Engineering MRB group. Approved
SEOs require Letter Coded problem numbers that
are controlled by the LBD Engineering MRB Group.
The following note shall be added to Sheet 1
of the SEO.
COORDINATED WITH LBD MATERIAL REVIEW BOARD
ENGINEERING PROBLEM NUMBER:
- CSEOs written by the Seller must be coordinated
with the LBD Engineering MRB group prior to
release by the supplier. CSEOs written by the
Seller require a Manufacturing Implementation
Plan (MIP) processed through the LBD Purchasing
Representative. When the Seller has contractual
design responsibility and LBD issues an SEO
against that drawing, LBD shall coordinate,
advance release, and send duplicate original
"600 Series" SEOs to the Seller.
- When a SEO/CSEO product requires LBD Planning
Action (to install a black-banded product),
the Master File Copy of the SEO/CSEO must be
received from the Seller with sufficient lead-time
to complete the Planning Action prior to the
product being received at LBD.
5.5. Material Substitution Requests.
- Material Substitutions are a change to Type
Design Data and require an EO/SEO to the applicable
drawing, or inclusion in the Approved Material
Substitution List (AMSL) or Part Specific Approved
Material Substitution List (PSAMSL) as applicable.
Sellers not authorized to create EO's/SEOs shall
submit material substitution requests on a Vendor
Information request (VIR) (Form DAC 26-23) through
the LBD Procurement Agent. Material substitutions
already listed in the AMSL or PSAMSL do not
require additional LBD authority.
The Seller is authorized to utilize the listed
substitutions within the guidelines and requirements
of the AMSL/PSAMSL.
- b. Seller with authority to create EO's/SEOs
shall submit material substitutions requests
to the Liaison Engineering group with the following
information:
- The coded problem number;
- The material substitute, if known;
- The specific effectivity, if applicable;
- The specific detail part numbers;
- The quantity of parts;
- The reason for the substitution (i.e.,
material shortage, etc.) and;
- A copy of the proposed material substitution
SEO.
5.6. Safe Life Parts
- Safe Life Parts (Sometimes also referred
to as "Life Limited" parts) are parts
that have been specially identified as critical
to the safety of the aircraft and have a specified
life. Fatigue life must therefore be assessed
any time one of these products is changed. Lists
of the Safe Life Part numbers for LBD products
can be found in LBD's Airworthiness Limitations
Instructions (reference following examples):
MDC-J0005 - DC-9 and MD-80
MDC-94K9000 - MD-90
MDC-J5752 - DC-10
MDC-K5225 - MD-11
MDC-96K9063 - 717
Safe Life parts must not be dispositioned in
such a way that the life is reduced. The Seller
shall include a listing of Safe Life Parts and
serial numbers, as applicable, with the shipping
documentation.
- Principal Structural Element (PSE) - are
a part (or more typically, a specific area or
zone of a part) that have been specially identified
as critical to the safety of the aircraft and
have specific crack growth and residual strength
characteristics. These characteristics must
therefore be assessed any time one of these
products is changed. PSEs for LBD products are
defined in LBD's Airworthiness Limitations Instructions
(reference following examples):
MDC-94K9000 - MD-90
MDC-K5225 - MD-11
MDC-96K9063 - 717
5.7. Coordination of Technical Problems
for Items on LBD Design Format:
- Seller may request technical assistance from
the LBD Liaison Engineering MRB group.
Note: Design improvement change requests/proposals
are processed on a Seller Change Proposal or
per the method specified in the Purchase Document
(Engineering Coordination Memo (ECM), Program
Coordination Memo (PCM), Vendor Information
Request (VIR), etc.).
- If the use of ECMs or PCMs is specified in
the Purchase Document, they are to be used for
technical questions/problems and sent directly
to the affected LBD Design group. In no case
are ECMs or PCMs to be used for any questions
regarding nonconforming product or material
substitution.
- Technical questions are addressed to the
LBD Engineering MRB group in cases where ECMs
and PCMs are not specified in the Purchase Document.
Seller shall coordinate with the LBD Engineering
MRB group (except when otherwise specified in
the Procurement Document) when questions arise
regarding, but not limited to, processes, drawings,
methods, materials, performance, and aerodynamics
on production aircraft. Technical problem and
MRB correspondence, sent between the Seller
and the LBD Liaison Engineering (MRB) group
are assigned a problem number prefix code. The
assigned problem number is unique and restricted
to one drawing number per problem. All subsequent
correspondence pertaining to that particular
problem will reference the original problem
number.
- Seller shall maintain a running log of sequential
numbers for problem coordination, and transmit
technical assistance requests and non-conformance
disposition requests to the LBD Engineering
MRB group with the following information as
applicable:
- Problem number;
- Part number;
- Part serial number;
- Effectivity;
- Quantity of parts rejected;
- Complete problem or non-conformance description,
including applicable sketches and drawing
zone number;
- Proposed disposition;
- Stress analysis, if applicable;
- Rejection form serial number;
- Copy of the proposed SEO;
- Copies of the appropriate drawings (if
unreleased in the LBD system);
- Historical information (if the problem
is a recurring problem);
- The LBD procurement representative (buyer)
name.
LBD Liaison Engineering will respond to technical
assistance requests with a return response containing
the LBD Liaison Engineering Log Number and a disposition
or instructions.
5.8. LBD MRB Dispositions: Non-conformance
(MRB) dispositions from LBD Liaison Engineering
will be provided either directly on the response
copy of the rejection document/form the Seller
submitted or as an attachment. The response will
also have a LBD Liaison Engineering Log Number.
The Seller shall copy the LBD Liaison Engineering
disposition onto the original rejection document
(or make a continuation sheet to the document)
and reference the LBD MRB Engineer's name, employee
number, and LBD response log number under the
disposition. Sellers without delegated QA MRB
shall submit the original MRB document and the
original response received from LBD to LBD Quality
Assurance for concurrence and acceptance of the
product.
6.0. Deliverable Airborne Software
6.1. This section is applicable to
a Seller developing, supplying, and maintaining
software for LBD. This section contains LBD specific
Software Quality Assurance (SQA) requirements,
mandates Seller's compliance with both RTCA/DO-178B,
as applicable for project specific SQA software
certification aspects, and D6-82479, Boeing Quality
Management System Requirements for Suppliers (BQMS),
Addendum 2, Quality System Requirements. Where
a conflict of requirements exists, the order of
precedence is LBD specific SQA requirements, RTCA/DO-178B,
and D6-82479, Addendum 2.
6.2. Seller providing LBD with software
or articles containing software shall prepare,
implement and maintain a Software Quality Assurance
Plan specifying the software quality assurance
program. The Seller shall document the plan in
accordance with the requirements of Data Item
Description Q-320, Software Quality Assurance
Plan. (Reference Seller's Supplier Data Requirements
List (SDRL)) The plan and any subsequent changes
thereto require LBD Software Quality Assurance
written approval prior to implementation.
7.0. Products of New Manufacture: The Seller
shall ensure that all products and materials are
of new manufacture and free of Foreign Object
Debris/Damage (FOD). All products and materials
delivered, and processes performed, shall meet
all specifications and requirements contained
in the Purchase Document including reference documents
specified therein.
8.0. Quality System Status: Sellers placed on
"Probation" shall not ship LBD product
unless authorized by LBD Quality Assurance.
9.0. Assistance: The Seller and their subcontractors
shall provide all reasonable assistance, facilities
and equipment to itinerant and/or resident LBD
and Regulatory Agency personnel.
10.0. Flammability Requirements: Seller shall
verify that interior articles that are certified
to Federal Aviation Regulation (FAR) 25.853 requirements
continue to meet such requirements for subsequent
production units. At LBD request, the Seller shall
provide proof of testing of articles to verify
their conformance to flammability requirements.
11.0. Technical Data Control and Acceptance:
After LBD acceptance of a product design, no changes
shall be made without written authorization from
LBD for any change which will or may affect:
- Interchangeability, performance, weight,
safety, reliability, service life, fit, form,
function, and maintainability;
- Federal Aviation Administration (FAA) certification;
or
- LBD Qualification status.
12.0. Products produced under this purchase document
line item containing metallic raw material from
foreign producers required to conform to federal,
military or industrial specifications shall be
procured in accordance with Douglas Material Specification
(DMS) 2201. When required, the Seller shall certify
to DMS 2201. A Seller's authorized Quality Assurance
representative shall sign the certification. The
Seller shall maintain on file a certification
traceable to each product listing the material
and the foreign producer's name and address.
13.0. The Seller and their subcontractors must
have LBD process approval, or use an LBD approved
processor when the process specification(s) identified
on LBD engineering drawings, specifications, or
this Purchase Document line item, are listed in
D1-4426, Approved Process Sources. D1-4426 is
accessible via the Internet at the following web
address: http://www.boeingsuppliers.com/d14426/
Approved Process Sources: Use of approved processors
by the Seller does not relieve the Seller from
verifying that the processor and the product conform
to all applicable process specification requirements.
The Seller shall submit a "Supplier Certificate
of Conformance" (Form DAC X2-455) when using
an approved processor.
14.0. The Seller's shipping documentation shall
include the following, when applicable:
- A copy of the approved Manufacturing Implementation
Plan (MIP) with all required signatures;
- A Serialized Components List identifying
parts with a sequentially assigned serial number.
The list shall contain the part numbers, part
change letters part nomenclature and part serial
numbers;
- The original LBD-issued Work Order, Form
DAC 26-114B, when used as a releasing document
communicating quality clause requirements;
- Interface Control Drawing (ICD) and/or Variability
Data (VR) data when an ICD plan is a contractual
requirement.
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