My company is an FAA certified repair station. We are currently gearing up to provide induction services i.e., disassembly, cleaning, parts preservation, etc. for a prime aerospace company. They are flowing down the requirements of AS9100 to us. After spending much time reading the requirements of AS9100, it appears to be geared toward manufacturing operations, which we don't do. My challenge is in trying to figure out how to tailor the requirements of AS9100 to our company and vice versa. This is my reason for joining this forum. I am hoping to find some guidance from folks who know more about this than I do. Any advice or insight is greatly appreciated.

Most elements of the standard will also apply to a service organization/operation.

Examples to consider:

Management Review
Quality System
Contract Review
Document Control
Process Control
Inspection and Testing
Control of NC Mat'l
Corrective/Preventive Action
Control of Quality Records
Internal Audits
Training
Servicing
Etc.

Our repair station (and mfg. operation) has been certified ISO 9001 since 1998 and AS 9100 since November 2001. We will be upgrading to AS 9100a this December. When you choose a registrar, you will have to work with them to determine the scope of your audit/certification and which elements apply. I would choose a registrar who has experience in auditing/certifying service organizations, preferably FAA certified repair stations.

If your client is willing to wait, and you are basically a repair and overhaul facility, AS9110 would probably be a better document for you to model your quality system around.

I don't know what is the hold up for the issuance of AS9110 and 9120. In the AAQG meetings, both documents had been reported as approved some months ago.

I certainly wish we could wait, unfortunately that is not an option for us now. I have been waiting for the release of the new AS9110 standard, but it appears that waiting has been in vain. When I asked our customer quality rep if they could possibly accept it in place of AS9100, I was told that wouldn't happen. Since we are a subcontractor for them, we must implement the AS9100 standard. The prevailing thinking of both our management and our customer quality rep is that there is a possibility that we may become more involved in some limited manufacturing for the customer in the future. Hence the need for us to be AS9100 compliant.

So far we have no requirement from the customer to become certified by an industry controlled other party, however that may change in the future, (I'll interject here customer=Boeing)

If it comes to that, I'm sure I'll be visting this site more frequently.

Thanks for your input.

I run the Quality system for an aerospace electronics manufacturing division, an electronics distribution division, and an FAA repair station, and I just created a new manual for AS9101A for all three divisions, so I know how you feel.

Keep in mind that you still have most of the processes that a manufacturing facility uses, Purchasing, inspection, calibration, configuration, work instructions, packaging, non-conforming material, etc., so writing the manual really isn't as hard as it looks. You just need to envision your facility as a production facility, and utilize the exceptions clause to the fullest for the pure manufacturing operations that you don't need or use. Your manual won't be all that big or in depth, and will still follow all of the requirements.

Also remember that if you are held to FAR 145 by the FAA, they are requiring that between April 2003 and April 2004 that you rewrite your repair manual to coincide with ISO 9000:2000, which AS9100 was modeled after. So you would have to do this anyway.

Good Luck

I just came back from a Boeing Symposium. They are "strongly encouraging" suppliers to become AS9100 registered.

We are currently performing an internal assessment for the Boeing Preferred Suppliers Program, which is much more than the requirements from AS9000 (however in the same direction).

When you are reviewing your Quality Management, you must have the corporate strategy in mind - hopefully you have one and it is known. From that point, you know the depth you need to go.

Cheers!

...Also remember that if you are held to FAR 145 by the FAA, they are requiring that between April 2003 and April 2004 that you rewrite your repair manual to coincide with ISO 9000:2000, which AS9100 was modeled after. So you would have to do this anyway...

I'm just starting to research AS9100 and FAR part 145 (no prior experience) and thought I'd check out this forum. Anyway, I came upon this statement.

Can someone tell me if this is an accurate statement? I've been browsing AC145-MAN, it does state that the repair station may use applicable portions of its ISO manual or other quality system to show compliance with part 145. Am I missing something?

The FAA publishes an "Advisory Circular" (AC) which tells you in detail what is wanted in your repair station manual. As far as I know the FAA does not impose ISO9000-2000.

I'm just starting to research AS9100 and FAR part 145 (no prior experience) and thought I'd check out this forum. Anyway, I came upon this statement.

Can someone tell me if this is an accurate statement? I've been browsing AC145-MAN, it does state that the repair station may use applicable portions of its ISO manual or other quality system to show compliance with part 145. Am I missing something?Hi Cari!
We have just transistioned from ISO9001:1994 Registered AS9001 Compliant to AS9100A Registered with 11 nonconformances. Our main customer is Honeywell and they are requiring their suppliers become AS9100 Registered and FAR part 145 also. I will be looking into this in the next few months and would love to see more posts on this subject, since it is new to me too!
The more we learn together the more we can share!

Paulahttp://elsmar.com/Forums/images/smilies/smile.gif
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The FAA publishes an "Advisory Circular" (AC) which tells you in detail what is wanted in your repair station manual. As far as I know the FAA does not impose ISO9000-2000.

Thanks Hal - AC145-MAN was the draft, I just downloaded AC145-9 today. Do you know if this AC addresses the changes/additions to Part 145 that will take effect Jan.4,2004?

...Our main customer is Honeywell and they are requiring their suppliers become AS9100 Registered and FAR part 145 also. I will be looking into this in the next few months and would love to see more posts on this subject, since it is new to me too!
The more we learn together the more we can share!..

Thanks for sharing your manual!! I've saved a copy, I'll be able to read it through later today.

We are a machine detail manufacturer and repair center. Ballscrews, acme lead screws, spindles, jack screws, roller screws, etc. I see in your manual that you design, develop and manufacture test equipment, controls and power supplies. Do you do repair of these items as well? Is this why they're requiring that you are a certificated repair station?

I too would like to see more info on this subject. I believe there are other parts, like Part 43 and Part 65, that will pertain to our company. I've done a search of the cove using "FAA" and I see we have a few covers who work for Certificated Repair Stations or otherwise deal with FAA regulations. I am jotting down questions as I review the AC for developing manuals - I'll start a "Part 145 for Dummies" thread. :p

Frankly - I'm glad your out there with me being new to this. We'll definitely be able to benefit from our shared experiences! :agree:

Cari: The FAA A/C145-9 covers what is required JAN 31. Be sure to call your new manual a "Repair Station Manual" not the old Inspection Procedure Manual.

Cari: The FAA A/C145-9 covers what is required JAN 31. Be sure to call your new manual a "Repair Station Manual" not the old Inspection Procedure Manual.

Got it - and thanks!!

We are a machine detail manufacturer and repair center. Ballscrews, acme lead screws, spindles, jack screws, roller screws, etc. I see in your manual that you design, develop and manufacture test equipment, controls and power supplies. Do you do repair of these items as well? Is this why they're requiring that you are a certificated repair station?

Hi Cari,

Yes we do repair them as well and that is the main reason for the requirement. It may be a little tricky because of the small facility we have and seperating the new manufacturing area from the repair area is a bit confusing. :confused: We have one stock room for parts. I think if as long as everything is identified and controlled it should not be a problem.

Paula

Hi All! :)
I need to prepare a gap analysis as to what 9100 demands more than 9001. With respect to actual implementation requirements. Theoretically, the I am trying to find out additional requirements in 9101 and their implications on implimentation. I am trying to grade the additional requirements on several lines, like documentation, requirement, legal binding, prime's responsibility, demonstration compliance etc.

If there are any comparison or mapping documents already available it would be of great help!

Any help in this regard is appreciated.

:thanx:

As an FYI - AS9100A is almost exactly the same as ISO 9001:2000. In fact, the differences are in BOLD type in AS9100A.

Hello. I work with a registrar and am familiar with the standard. The new AS9100B checklist for the AS9100 standard includes 288 additional points on top of ISO 9000:2000 (those points are in bold). If you are AS certified, you can also receive ISO 9000:2000 certification at the same. Not sure if people know that. :D

:biglaugh: Hello all! I have been busy writing our Repair Station Manual to become FAR Part 145 certificated. We are also ISO9001:2000/AS9100A Registered. We are getting ready for recertification to AS9100B by November. My head is spinning because we are an OEM that does repair and overhaul. We set up the facility so that there is a designated Repair Station seperate from the manufacturing facility. In the Repair Station Manual, I have referenced some of our AS9100 Quality System Processes and Procedures, what I need to know is if that is cool? Any input would be greatly appreciated. Thanks, Paula

:biglaugh: Hello all! I have been busy writing our Repair Station Manual to become FAR Part 145 certificated. We are also ISO9001:2000/AS9100A Registered. We are getting ready for recertification to AS9100B by November. My head is spinning because we are an OEM that does repair and overhaul. We set up the facility so that there is a designated Repair Station seperate from the manufacturing facility. In the Repair Station Manual, I have referenced some of our AS9100 Quality System Processes and Procedures, what I need to know is if that is cool? Any input would be greatly appreciated. Thanks, Paula
I don't see a problem since you are one company with one quality system. You've probably referenced your IPM in the AS9100 QSM. Right.

No, I haven't mentioned the Repair Station in our QSM...yet. I am not sure if I have to or want to because of the different requirements of the FAA and AS9100B.

We were purchased by another FAR Part 145 Certified Company in Feb 04. They wanted to keep our name the way it is because we have been around for 37 years. They are not an ISO Registered company at this time and didn't want to add another rating to thier FAR Part 145 certificate because of the name change thing. The owner explained that we have to operate as two separate companies: Company X Inc. Certified Repair Station#M79R790N and Company X Inc. OEM, Design Manufacturer,ISO9001:2000/AS9100B Registered.
This is where I get confused. Do I have to write totally seperate procedures for the repair station covering things such as; corrective action, preventive action, Internal Audits, Document Control, Control of Records, etc.?
I don't believe I do, but when our registrar comes to audit us, I am very concerned how deep they will be allowed to probe into the Repair Station and how it will effect the overall assessment. In other words how much authority will the Quality System have over the FAA Repair Station Manual's Quality System other than the referenced QOP's and SOP's and a few referenced forms?

Paula:confused:

No, I haven't mentioned the Repair Station in our QSM...yet. I am not sure if I have to or want to because of the different requirements of the FAA and AS9100B.

We were purchased by another FAR Part 145 Certified Company in Feb 04. They wanted to keep our name the way it is because we have been around for 37 years. They are not an ISO Registered company at this time and didn't want to add another rating to thier FAR Part 145 certificate because of the name change thing. The owner explained that we have to operate as two separate companies: Company X Inc. Certified Repair Station#M79R790N and Company X Inc. OEM, Design Manufacturer,ISO9001:2000/AS9100B Registered.
This is where I get confused. Do I have to write totally seperate procedures for the repair station covering things such as; corrective action, preventive action, Internal Audits, Document Control, Control of Records, etc.?
I don't believe I do, but when our registrar comes to audit us, I am very concerned how deep they will be allowed to probe into the Repair Station and how it will effect the overall assessment. In other words how much authority will the Quality System have over the FAA Repair Station Manual's Quality System other than the referenced QOP's and SOP's and a few referenced forms?

Paula:confused: Just some thoughts I had.



The FAA can make life miserable for you. I would worry more about them than the ISO auditor.
I assume your as9100 scope does not include the Repair Station.
Which company controls the documents they both use? How do you describe the control of the OEM QS documents for the Repair Station? See no.1 above.

Thanks for the response, Al.

1. I hope to have a wonderful working relationship with the FAA! :)

2. No I will not be adding the repair station under the scope of our AS9100 registration, but...my registrar informed me that if our customer requires us to become FAR Part 145 that they might check to see that we follow the procedures we have established.
I will have a copy of the referenced Quality System processes and procedures in the Technical Library which will be located inside the repair station. These copies will be controlled in accordance to our Document Control procedure. I think it shoud work out ok.

3. The repair station manual has a manual revision process which basically is written to comply with the same procedures we use in AS9100.

Thanks for the input.

Paula

First: The FAA people that we have been involved with over the years have been sharp and reasonable. The thing I always remember is that we are dealing with "Legal" regulations when we deal with FAA. ISO is not a legal requirement. The way I handled the new Repair Station Manual was to reference the AS9100 manual. Not the specific second level procedures. I assume the procedures are referenced in the appropriate section of your AS9100 manual. In the quality manual I referenced the Repair Station Manual. According to the new regulations we are required to have a Quality manual. My problem is going to be the new Repair Station training procedures that we are required to have by April next year. Anybody work this training problem yet?

First: The FAA people that we have been involved with over the years have been sharp and reasonable. The thing I always remember is that we are dealing with "Legal" regulations when we deal with FAA. ISO is not a legal requirement. The way I handled the new Repair Station Manual was to reference the AS9100 manual. Not the specific second level procedures. I assume the procedures are referenced in the appropriate section of your AS9100 manual. In the quality manual I referenced the Repair Station Manual. According to the new regulations we are required to have a Quality manual. My problem is going to be the new Repair Station training procedures that we are required to have by April next year. Anybody work this training problem yet?

Luckily the R&O which recently hired me to be their QA Mgr has had an excellent training program. We'll have to work on the recertification requirement but I don't forsee much of a problem there.

Luckily the R&O which recently hired me to be their QA Mgr has had an excellent training program. We'll have to work on the recertification requirement but I don't forsee much of a problem there.
Hello Arolon, would you care to share a little more information about your company's training program, please:D Are you strictly an R&O facility or do you manufacture also?

We just went through our AS9100B Assessment Audit with only one minor nonconformance. We contracted a new Registrar this time and it was a RAB witnessed audit, which went very well. Now that its over, I am back to the FAA Part 145, Repair Station Manual.

We have already been through the Repairman Certification Test and are almost ready for the demonstration and inspection phase.

I am attaching the Training Procedure that is included in our RSM, have a look and feel free to comment.

Thanks, :thanx:
Paula