CAGE Code 81205
Production Equipment and Special Tooling
Quality Standard
DOCUMENT NUMBER: RELEASE/REVISION: RELEASE/REVISION DATE:
D950-11059-1 G
TECHNICAL CONTENT OWNER:
May 14, 2021
SUPPLIER QUALITY HM-01-D77A
Timothy R. Ditch has Quality Ownership RAA
(timothy.r.ditch@boeing.com)
All revisions to this document must be approved by the technical content owner before release.
Not subject to U.S. Export Administration Regulations (EAR) (15 C.F.R. Parts 730-774) or U.S.
International Traffic in Arms Regulations (ITAR), (22 C.F.R. Parts 120-130)
Copyright © 2021 Boeing. All rights reserved.
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Document
Information
Original
Release Date Contract Number
September 3, 2008
Notes and Li
m
i
tations
This document does not contain proprietary information and may be reproduced without the permission
of The Boeing Company. It will be the responsibility of the user to maintain the current version.
This document contains Non-technical / Administrative Data Only.
Authorization for Release
AUTHOR:
William J. Petry
3H1
Sept 03, 2008
CHECK:
Joseph M. Hale
Org. Number
815S
Date
Sept 03, 2008
CONCURRENCE:
Frank M. Foeller
Org. Number
D101
Date
Sept 03, 2008
CONCURRENCE:
Michael W. Yarwood
Org. Number
D78E
Date
Sept 03, 2008
CONCURRENCE:
Daryl E. Yochum
Org. Number
D70
Date
Sept 03, 2008
Org. Number
Date
CONCURRENCE:
Christopher B. Rudolph
091
Sept 03, 2008
APPROVAL:
Thomas J. Spiegel
Org. Number
D500
Date
Sept 03, 2008
DOCUMENT RELEASE:
Scott B. Pace
Org. Number
G-823A
Date
Sept. 3, 2008
Org. Number
Date
Copyright
© 2021 Boeing. All rights
reserved.
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Table of
Contents
1.0 Introduction and General Requirements ..........................................................................6
1.1 Introduction .........................................................................................................6
1.2 General Requirements ........................................................................................... 6
1.3 Seller-Subcontractor General Requirements ...................................................... ..8
1.4 Seller Communication...........................................................................................9
2.0 Seller Asset Capabilities.............................................................................................. 10
2.1 Scope................................................................................................................... 10
2.2 Requirements...................................................................................................... 10
3.0 Configuration Management
3.1 Scope……........................................................................................................... 13
3.2 Requirements…...................................................................................................13
3.2.1 Boeing-defined Assets.......................................................................................13
3.2.2 Seller-defined Assets….....................................................................................13
3.3 Seller Asset Periodic Inspections and Asset Acceptance…................................14
4.0 Asset Design/Definition…........................................................................................... 15
4.1 Scope................................................................................................................... 15
4.2 Requirements…...................................................................................................15
4.3 Design/Definition Approval................................................................................16
4.4 Design/Definition Requirements.........................................................................17
5.0 Data Elements.............................................................................................................. 18
5.1 Scope…............................................................................................................... 18
5.2 Requirements….................................................................................................. 18
5.3 Asset Specifications / Engineering Definition Requirements….........................18
5.4 Asset Identification............................................................................................. 18
5.5 Asset Usage Instruction.......................................................................................18
5.6 Periodic Inspection Plans.................................................................................... 19
6.0 Fabrication, Rework, and Modification....................................................................... 20
6.1 Scope................................................................................................................... 20
6.2 Requirements…...................................................................................................20
6.3 Initial Fabrication, Rework, and Modification…................................................20
6.4 Asset Material…………………………………................................................. 21
6.5 Coordinate Measuring Systems (CMS) Measurement…....................................21
6.6 Master Coordination……………………………............................................... 22
7.0 Special Processes…..................................................................................................... 24
7.1 Scope…............................................................................................................... 24
7.2 Requirements.......................................................................................................24
8.0 Acceptance…............................................................................................................... 25
8.1 Scope................................................................................................................... 25
8.2 Requirements…...................................................................................................25
8.3 Asset Acceptance Methods................................................................................. 26
8.4 Proof Load Test...................................................................................................28
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9.0 Periodic Inspection.......................................................................................................29
9.1 Scope...................................................................................................................29
9.2 Requirements…...................................................................................................29
9.3 Periodic Inspection Plans…................................................................................ 31
10.0 Each Use Condition Checks.........................................................................................34
10.1 Scope…...............................................................................................................34
10.2 Requirements...................................................................................................... 34
11.0 Manufacturing Work Instructions…............................................................................36
11.1 Scope...................................................................................................................36
11.2 Requirements….................................................................................................. 36
12.0 Production Process Verification and Asset Relationship….........................................37
12.1 Scope…............................................................................................................... 37
12.2 Requirements.......................................................................................................37
12.3 Communication Requirements…........................................................................37
13.0 Preventive Maintenance…...........................................................................................38
13.1 Scope................................................................................................................... 38
13.2 Requirements…...................................................................................................38
13.3 Preventive Maintenance Plans…........................................................................ 39
13.4 Preventive Maintenance …................................................................................. 39
14.0 Protection and Storage................................................................................................. 41
14.1 Scope................................................................................................................... 41
14.2 Requirements…...................................................................................................41
14.3 In Use / Active….................................................................................................41
14.4 Not in Use / In-Active…..................................................................................... 41
14.5 Storage.................................................................................................................42
15.0 Nonconformance…...................................................................................................... 43
15.1 Scope................................................................................................................... 43
15.2 Requirements…...................................................................................................43
16.0 Potential Product Impact..............................................................................................46
16.1 Scope................................................................................................................... 46
16.2 Requirements…...................................................................................................46
17.0 Receiving and Shipping…........................................................................................... 48
17.1 Scope................................................................................................................... 48
17.2 Requirements.......................................................................................................48
17.3 Receiving….........................................................................................................49
17.4 Shipping….......................................................................................................... 50
18.0 Post Production and Spares..........................................................................................52
18.1 Scope…............................................................................................................... 52
18.2 Requirements…...................................................................................................52
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19.0 Records Requirements..................................................................................................53
19.1 Scope................................................................................................................... 53
19.2 Requirements.......................................................................................................53
19.3 Records…............................................................................................................55
20.0 Definitions of General Terms…...................................................................................59
21.0 References…................................................................................................................65
List of Tables
Table 1: Seller Approval Capability Level Requirements…...............................................10
Table 2: Seller Asset Approval Type / Documented Information Requirements................11
Exhibits:
A. Example of Screening Report.….....................................................................................66
B. Example of Certificate of Conformance (CoC).…..........................................................67
Appendix:
A. Quality Standard Document Map.....................................................................................68
B. Change Record.................................................................................................................69
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1.0 Introduction
and General
Requirement
s
1.1 Introduction
This document defines The Boeing Company quality requirements for
Production Equipment, Special Tooling (ST) and Special Test Equipment
(STE). These requirements are established for control by means of a
recognized Quality Management System (QMS) and requirements contained
in – Requirements for Aviation, Space and Defense Organizations; and
Federal Acquisition Regulation (FAR), Part 45 and Part 52.245-1
(Government Property); Defense Federal Acquisition Regulations
Supplement (DFARS) 252.245; Federal Aviation Regulation, Title 14: Part
21, Subpart G, “Production Certificates”; including sanctioned International
Aerospace Quality Group (IAQG) AS/EN/JISQ 9100 Quality Management
System (QMS) standards.
This document applies to all Boeing-owned assets, Government-owned assets and
Seller-owned assets that are accountable to The Boeing Company. Boeing
procurement may include asset design/definition, fabrication, inspection,
maintenance items, and can include assets used to produce product during the
execution of a Boeing Purchase Contract by the Seller and/or their subcontractors.
This document is not intended to contradict any Boeing or Government Property
Management requirements for assets. Seller must formally address any conflict of
requirements with Buyer’s Authorized Procurement Agent (APA) reference
section 1.4 (Seller Communication).
This document applies to all asset types that include Special Tooling (ST)
including mylar type layouts; Special Test Equipment (STE); and Production
Equipment, including Overhead Mechanical Handling Equipment.
Property and/or materials excluded from this requirement include:
1. Capital Equipment.
2. Portable/Perishable Tools, Hand Tools or General Purpose Equipment.
3. Shop Aid / Manufacturing Aid type assets.
4. Seller defined and owned assets. (see sec. 4.3 for specific applicability)
a. Seller defined and owned assets used to produce Boeing product must
meet all configuration, usage, document control and verification
requirements as defined in AS/EN/JISQ 9100 Quality Management
System (QMS) standards.
1.2 General
Re
quir
ements
This document applies to all Boeing owned assets and Government owned assets
accountable to Boeing. This includes Boeing provided Asset Engineering
Design/Definition being used to realize Seller owned and Seller accountable
assets used to produce Boeing products.
All assets must meet the requirements as defined in a Boeing approved Purchase
Contract. The following may be in part or fully imposed as part of a Purchase
Contract: Special Business Provision (SBP), D33200-1 (Boeing Supplier’s
Tooling), Supplier Specification Plan (SSP), Statement of Work (SOW), D33207-
1 (Supplier Statement of Work for Special Tooling and Special Test Equipment -
BDS, BR&T, BT&E, BGS (Government Programs), Asset Design/Definition
and/or Product Engineering Definition.
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When imposed contractually, Seller must comply with the requirements of this
document for the following:
Define, fabricate, rework, modify, receive, use, maintain, and/or store an asset
during the performance of a Purchase Contract or during sustained
procurement that requires the continued use of Boeing accountable assets.
Define, fabricate, rework, modify and delivery of an asset during Purchase
Contract execution.
The Seller is required to have a current AS9100 certificate from a Boeing
recognized certification body when a Seller receives, uses, maintains, and/or
stores a Boeing accountable asset in support of a Boeing Purchase Contract.
The Seller is required to have a current AS9100 certificate or an accredited
Quality Management System (QMS) certification issued by an accredited
Certified Body where a tooling capability is defined within the Certificate Scope
or must satisfy documented information requirements per section 2 (Seller
Capability) Table 1 (Design/Definition – Fabrication, Rework, Modification –
Inspection/Verification) and Table 2 (Design Only and/or Fabrication Only) when
Seller:
Defines, fabricates, reworks, modifies and delivers an asset during Purchase
Contract execution.
Seller including all Seller sub-divisions and subsidiaries must maintain
documented information, processes, training and equipment to implement and
maintain the requirements of this document, this includes any Seller capability
used to realize, conform, configure, or accept Boeing accountable assets. Seller’s
internal audit process must include the requirements of this document and be
performed in accordance with existing Quality Management System (QMS)
requirements.
Boeing reserves the right to conduct surveillance at Seller’s facilities,
including interdivision facilities and subcontractors regardless of Quality
Management System (QMS) dependency to determine the contracted Seller’s
compliance to the requirements of this document. Boeing also reserves the
right to make the final determination of the Seller’s asset engineering
definition, fabrication, inspection, and acceptance capabilities. (Reference
Section 2.0 Table 1 and Table 2 for the “Capability Level / Approval Type”
matrix). Seller’s recognized asset capabilities are documented and maintained
in Boeing’s supplier quality data system.
Boeing accountable assets provided in support of Boeing Purchase Contracts
must be used for product realization and must be controlled in accordance
with this document. Sellers identifying alternate methods of product
realization in lieu of Boeing accountable assets (Ref. section 15.2 H&I), must
obtain formal authorization (ref. section 1.4 Seller Communication). Assets
not in use must be processed per Purchase Contract closeout requirements
(Ref. E000 Supplier Requirements for Buyer/Government/Customer Property
Management and/or D33113-1 Accountability of In-Plant/Out-Plant Special
(Contract) Tools) or formally submit request for excess asset disposition (ref.
section 1.4 Seller Communication).
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Seller must provide written notice (ref. section 1.4 Seller Communication) of
any proposed plans for moving Seller’s manufacturing location or moving
assets or other equipment utilized in the manufacture of the Boeing product
to another facility. In no event must Seller proceed with implementing such
plans prior to obtaining prior written approval (ref. section 1.4 Seller
Communication).
Seller is required to formally communicate within 30 days (ref. section 1.4
Seller Communication) for evaluation of potential impact to Boeing
recognized asset capabilities when changes to Seller’s organizational
structures, staffing levels, training, processes, procedures, including Quality
Management System (QMS), equipment or infrastructure occur.
If during Boeing Purchase Contract execution the Seller or its subcontractors
are not capable of performing a required asset function or capability, Seller
must immediately and formally contact Boeing (ref. section 1.4 Seller
Communication) for resolution.
1.3 Subcontractor General Requirements
Boeing reserves the right to conduct surveillance at Seller’s facility including
Sellers interdivision facilities where asset work transfers occur. Boeing also
reserves the right to conduct surveillance at Seller’s subcontractors and any
subsequent subcontractors where asset work transfer occurs in support of a
Boeing Purchase Contract.
Seller must impose and flow down the requirements contained in this document to
all subcontractors and subdivisions where Boeing assets are procured, transferred,
and/or used in support of Boeing Purchase Contracts. Seller is responsible for
subcontractor conformance to the requirements of this document. This includes
interdivision asset transfers where interdivision quality system is independent and
a Boeing recognized asset capability is not active.
Where Seller does not maintain proficiency to determine a subcontractor’s
capability (Ref. section 2.0 – Seller Asset Capability) to support a Boeing
accountable asset, Seller must formally contact Boeing (ref. section 1.4 Seller
Communication) to request assistance/guidance in subcontractor capability
determination.
When Seller is not capable of performing asset process-initial fabrication, rework,
modification, acceptance, or periodic inspection the Seller must take the
appropriate actions to ensure asset process is accomplished.
Typical options include:
1. Shipping asset to Boeing.
2. Asset process performed by Boeing at Seller’s site.
3. Third-party asset process arranged by seller.
If asset inspection or acceptance is delegated by the Seller, all inspection and
acceptance must be in compliance with section 8.0 (Acceptance) of this
document. For Boeing identified configuration critical assets, inspection or
acceptance delegation requires prior written technical approval (ref. section 1.4
Seller Communication).
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Excluding Boeing capability assessments, the Seller is responsible for having a
documented process to determine third-party capability when engaging a third
party per section 2 (Seller Asset Capability) and section 1.3 (Subcontractor
General Requirements) and any applicable Boeing contractual requirements.
The Seller’s subcontractors, including interdivisions asset capability
determination, evaluation and approval is the responsibility of the Seller and must
satisfy established Quality Management System (QMS) requirements for Control
of Externally Provided Processes, Products, and Services and must be in
compliance with requirements in this document. The Seller must demonstrate to
Boeing with objective evidence that the Seller’s subcontractors and Seller
interdivision approvals are acceptable with regard to asset capability and
compliance requirements.
Seller may acknowledge an existing asset capability approval maintained by a
subcontractor. Subcontractors asset capability recognization is the responsibility
of Seller and must satisfy the requirements of this document and established
Quality Management System (QMS) requirements. Seller is required to maintain
objective evidence of subcontractor approval. Documented information of the
subcontractors third party approvals, are recognized, as asset capability, and asset
controls when applicable.
1.4 Seller Communication
When formal customer communication is required in support of a Purchase
Contract, Seller must submit formal written request for support. Where contract
requirements identify direct Boeing technical support, formal request will be
directly submitted to Boeing Authorized Technical group in addition to Buyer’s
Authorized Procurement Agent (APA). When instructed, Seller will submit
Technical Supplier Information Request (TSIR) when formal technical
instructions are needed to satisfy contract.
When instructed or required by a Purchase Contract (Ref. section 1.2 General
Requirements), Seller must submit any required asset documents, data, results or
reports through Boeing’s approved electronic data system (e.g., Supplier Data
Requirements List (SDRL), Customer/Supplier Data Transmittal (CSDT),
Integrated Data Management System (IDMS), Vendor Inventory Process (VIP),
authorized secured transmittal platform (e.g. Message Courier).
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2.0 Seller Asset Capabilities
2.1 Scope
This section defines a consistent method of determining the technical and process
control capability of a Seller relative to the asset engineering design/definition,
fabrication, inspection, acceptance, usage, and maintenance.
2.2 Requirements
A. Seller’s capabilities to perform necessary elements of asset management
throughout the life cycle of assets will be evaluated, assessed, and tracked by
Boeing.
B. Seller must demonstrate proficiency to Boeing using the capability
requirements defined in Table 1 (Seller Approval Capability Level
Requirements), and any specific asset requirements defined in Purchase
Contract, before performing a function listed below:
1. Engineering Design/Definition. (Section 4)
2. Fabrication, Rework, or Modification. (Section 6)
3. Conventional and digital measurement and physical coordination. (Section
6, 7, 8, 9)
4. Visual and dimensional inspection. (Section 8, 9)
5. User / Condition Check. (Section 10)
Table 1: Seller Approval Capability Level Requirements
Approval Capability Level
Design /
Definition
Fabrication,
Rework, or
Modification
Inspection /
Verification
User /
Condition
Check
Documented Information Required for Approval:
Configuration Management
(Ref. Section 3)
X
X
X
X
Design/Definition
(Ref. Section 4)
X
Data Elements
(Ref. Section 5)
X
X
X
X
Fabrication, Rework, and Modification
(Ref. Section 6)
X
X
Special Process
(Ref. Section 7)
X
X
Acceptance
(Ref. Section 8)
X
X
X
Periodic Inspection
(Ref. Section 9)
X
X
Each Use Condition Check
(Ref. Section 10)
X
X
X
Manufacturing Work Instructions
(Ref. Section 11)
X
Production Process Verification and Asset
Relationship
(Ref. Section 12)
X
X
X
X
Preventive Maintenance
(Ref. Section 13)
X
X
X
Protection and Storage
(Ref. Section 14)
X
X
X
Nonconforming Assets
(Ref. Section 15)
X
X
X
X
Potential Product Impact
(Ref. Section 16)
X
X
X
X
Receiving and Shipping
(Ref. Section 17)
X
X
X
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Post Production and Spares
(Ref. Section 18)
X
X
X
Records Requirements
(Ref. Section 19)
X
X
X
X
How to read table
Top row defines levels of approval and capability types. (note: Seller may be approved to one or multiple Discipline Categories)
Left Column defines documented information required to meet a desired capability and approval type.
Process documented information required “X”
C. Seller must develop and maintain documented information for Boeing Asset
Approval recognition per requirements defined in Table 2 (Seller Asset
Approval Type /Documented Information Requirements), and any specific
asset requirements defined in Purchase Contract, as listed below:
Table 2: Seller Asset Approval Type / Documented Information Requirements
Seller Types:
Receive/Use/Maintain
Design only
Fabrication only
Seller Procedure Requirements:
General
Requirements
Maintain accredited QMS
certification
Sub tier approvals for offload
of asset services
Maintain accredited QMS
certification
Sub tier approvals for offload
of asset services
Maintain accredited QMS
certification
Sub tier approvals for offload
of asset services
Section 3
Configuration
Management
Sec. 3.2 – Configuration
Management Requirements
Sec. 3.2.1 - Boeing-defined
Sec. 3.2.2 - Seller-defined
Sec. 3.3 - Seller Asset Periodic
Inspections and Asset
Acceptance
Sec. 3.2 – Configuration
Management Requirements
Sec. 3.2.1 - Boeing-defined
Sec. 3.2.2 - Seller-defined
Sec. 3.3 - Seller Asset Periodic
Inspections and Asset
Acceptance
Sec. 3.2 – Configuration
Management Requirements
Sec. 3.2.1 - Boeing-defined
Sec. 3.2.2 - Seller-defined
Sec. 3.3 - Seller Asset Periodic
Inspections and Asset
Acceptance
Section 4
Design/Definition
Sec. 4.2. - Design Procedure
Requirement
Sec. 4.3. – Design Approval
Sec. 4.4 – Design
Requirements
Sec. 4.2 - Design Procedure
Requirement
Sec. 4.3 – Design Approval
Sec. 4.4 – Design
Requirements
Sec. 4.2 - Design Procedure
Requirement
Sec. 4.3 – Design Approval
Sec. 4.4 – Design
Requirements
Section 5
Data Elements
Sec. 5.2 - Data Element
Requirements
Sec. 5.3 - Asset
Specification/Engineering
Requirements
Sec. 5.4 - Asset Identification
Sec. 5.5 – Asset Usage
Instructions
Sec. 5.6 Periodic Inspection
Plans
Sec. 5.2 - Data Element
Requirements
Sec. 5.3 - Asset
Specification/Engineering
Requirements
Sec. 5.4 - Asset Identification
Sec. 5.5 – Asset Usage
Instructions
Sec. 5.2 - Data Element
Requirements
Sec. 5.3 - Asset
Specification/Engineering
Requirements
Sec. 5.4 - Asset Identification
Section 6
Fabrication, Rework,
and Modification
Sec. 6.2 – Requirements
Sec. 6.3 - Initial Fabrication,
Rework and Modification
Sec. 6.4 – Asset Material
Sec. 6.5 - Coordinate
Measuring Systems (CMS)
Measurement
Sec. 6.6 Master Coordination
Sec. 6.2 – Requirements
Sec. 6.3 - Initial Fabrication,
Rework and Modification
Sec. 6.4 – Asset Material
Sec. 6.5 - Coordinate
Measuring Systems (CMS)
Measurement
Sec. 6.6 Master Coordination
Section 7
Special Processes
Sec. 7.2 – Special Process
Requirements
Sec. 7.2 – Special Process
Requirements
Section 8
Acceptance
Sec. 8.2 – Requirements
Sec. 8.3 - Asset Acceptance
Methods
Sec. 8.4 - Proof Load Test
Sec. 8.2 – Requirements
Sec. 8.3 - Asset Acceptance
Methods
Sec. 8.4 - Proof Load Test
Section 9
Periodic Inspection
Sec. 9.2. - Requirements
Sec. 9.3 - Periodic Inspection
Plans
Section 10
Each Use Condition
Check
Sec. 10.2 - Requirements
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Section 11
Manufacturing Work
Instructions
Sec. 11.2 - Requirements
Section 12
Production Process
Verification and Asset
Relationship
Sec. 12.2 - Requirements
Sec. 12.3 - Communication
Section 13
Preventive
Maintenance
Sec. 13.2 - Requirements
Sec. 13.3 - User Maintenance
Sec. 13.4 - Preventive
Maintenance
Sec. 13.5 - Preventive
Maintenance Plans
Section 14
Protection and
Storage
Sec. 14.2 - Requirements
Sec. 14.3 - Asset In Use
Sec. 14.4 - Asset Not In Use
Sec. 14.5 - Storage
Sec. 14.2 - Requirements
Sec. 14.3 - Asset In Use
Sec. 14.4 - Asset Not In Use
Sec. 14.5 - Storage
Section 15
Nonconformance
Sec. 15.2 - Requirements
Sec. 15.2 - Requirements
Section 16
Potential Product
Impact
Sec. 16.2 - Requirements
Section 17
Receiving and
Shipping
Sec. 17.2 - Requirements
Sec. 17.3 - Receiving
Sec. 17.4 - Shipping
Sec. 17.2 - Requirements
Sec. 17.3 - Receiving
Sec. 17.4 - Shipping
Section 18
Post Production and
Spares
Sec. 18.2 - Requirements
Section 19
Records
Requirements
Sec. 19.2 - Requirements
Sec. 19.3 - Records
Sec. 19.2 - Requirements
Sec. 19.3 - Records
Sec. 19.2 - Requirements
Sec. 19.3 - Records
How to read table
Top row defines levels of Discipline Categories (note: Seller may be approved to one or more Discipline Categories)
Left Column defines documented information required to meet Discipline Category compliance.
Section criteria defines the minimum process compliance to achieve approval.
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3.0 Configuration Management
3.1 Scope
This section establishes standardized asset configuration management
requirements and objectives based on principles that ensure products and services
meet customer, Boeing, and regulatory requirements throughout asset lifecycle.
3.2 Requirements
A. The Seller is required to create documented information to control
Configuration Management processes of all assets and has clear requirements
that define the roles and responsibilities established for:
1. Documented Information for Requirements, Specifications,
Design/Definition, Verification, Validation, and Acceptance.
2. Planning.
3. Identification and Traceability.
4. Change Control and Variance Management.
B. Seller must ensure that all assets are at the designated configuration
levels/revisions for the part or assembly being produced, or the installation
being performed. When appropriate, Seller must initiate coordination and
negotiation with Boeing (ref. section 1.4 Seller Communication) for proper
configuration alignment.
3.2.1 Boeing-defined Assets
A. Seller must implement, at the designated effectivity or incorporation point,
Boeing initiated asset configuration levels/revisions including asset
engineering design/definition, asset usage instructions, and asset inspection
instructions.
B. If Boeing-defined asset engineering design/definition is not available at Seller
or their subcontractors the Seller must formally coordinate with Boeing (ref.
section 1.4 Seller Communication) to obtain instructions for resolution.
C. For Boeing provided assets Seller must, regardless of capability level, take
action upon notification of a configuration revision, to ensure configuration
level revision incorporation at the designated effectivity or incorporation point
with no impact to Boeing production schedules unless otherwise coordinated
with Boeing (ref. section 1.4 Seller Communication).
3.2.2 Seller-defined Assets
A. Seller must ensure configuration levels/revisions are integrated into the asset
family to support the designated effectivity or incorporation point.
B. Seller Fabricated, Reworked, and Modified Assets Seller must, based on
capability level, initiate actions to incorporate appropriate configuration
levels/revisions into asset at the appropriate effectivity or incorporation point.
Seller must initiate coordination and negotiation with Boeing (ref. section 1.4
Seller Communication) for proper configuration alignment.
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3.3 Seller Asset Periodic Inspections and Asset Acceptance
A. Seller must ensure the correct configuration of all assets, including multi-
configuration assets, used in conjunction with any production equipment
being used during the manufacture of Boeing products.
B. When configuration alignment issues arise during asset periodic inspection
and asset acceptance, Seller must immediately and formally submit technical
request (ref. section 1.4 Seller Communication) for resolution.
C. Seller must verify asset configuration meets Purchase Contract and/or product
engineering requirements prior to use. Asset configuration verification may
include performing asset acceptance per section 8 (Acceptance).
D. If Seller is unable to verify asset configuration, perform asset validation
and/or asset periodic inspection the Seller must immediately and formally
submit technical request (ref. section 1.4 Seller Communication) for
instructions when:
1. Asset design/definition is not available. (i.e., master tooling, digital
definition, or asset engineering drawings or definition).
2. Provided asset design/definition engineering conflicts with current product
engineering (configuration alignment, dimensional issues, etc.)
3. Where physical or digitally defined Category I (CAT I) master tool
configuration issues are identified, Seller must immediately notify Boeing
(ref. section 1.4 Seller Communication) for resolution. Typical
instructions may include but are not limited to the following:
a. Formal Purchase Contract exception for asset configuration
responsibility (i.e., purchase contracts letter, engineering change
notice, statement of work).
b. Specification Outside Processing (SPECO) instructions for asset
controls including asset configuration.
c. Purchase Contract change or special provision that provides asset
configuration instructions as part of Purchase Contract language.
E. When Seller identifies any Boeing provided Asset or any formal document
where Asset configuration is suspect, the Seller must initiate a
nonconformance and identify, document, and segregate any asset from
manufacturing use until receipt of formal resolution or alternative method is
authorized in accordance with this document. When correction of
nonconformance exceeds Seller capability (Ref section 2 Seller Capability),
Seller must formally contact Boeing (ref. section 1.4 Seller Communication)
for resolution.
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4.0 Asset Design/Definition
4.1 Scope
This section defines requirements associated with asset design/definition
engineering processes and provides quality requirements for the creation of initial
and revised asset engineering design/definitions including all media forms, such
as, but not limited to: text files, 2D drawings, 3D models, datasets, mylar type
layouts, and numerically controlled (NC) programs.
4.2 Requirements
A. Seller must demonstrate asset design/definition system capability and
proficiency (i.e., personnel, system capabilities, capacity). Seller must be
deemed capable for asset design/definition when required to support Boeing
Purchase Contracts (Ref. section 1.2 General Requirements), Seller must
maintain compliance and approval to sanctioned International Aerospace
Quality Group (IAQG) AS/EN/JISQ 9100 Quality Management System
(QMS) standards for Design and Development of Products and Services.
B. Sellers must maintain documented information to develop, control, revise,
and/or maintain asset designs/definition for all Boeing accountable assets,
government and seller assets accountable to Boeing. This includes any Boeing
provided asset design/definition controlling configuration of seller owned
assets.
C. Seller’s documented information for asset design/definition must:
1. Maintain design/definition configuration, including changes, must
conform and be traceable to contracted product engineering.
2. Define asset intent such as Category I (CAT I) master tool use, product
testing, product verification regardless of asset category and where
configuration critical asset is identified by program or Purchase Contract.
3. Define and maintain asset usage instructions and will be traceable to the
asset design/definition, is under revision control, and is required when any
asset:
a. Is complex
b. Has critical indexing methods
c. Has multiple configuration settings
d. Usage cannot be easily communicated on the asset or within the
manufacturing work instructions (i.e., shop traveler, work order)
e. Is critical for safe asset operation and usage
D. Sellers using digital product definition data for any phase of asset
design/definition, must meet the requirements of D6-51991 (Quality
Assurance Standard for Digital Product Definition at Boeing Sellers).
E. Asset engineering design/definition is generated when:
1. The asset produces, supports or verifies an end item.
2. The asset controls configuration critical product or assemblies.
3. The asset interfaces or controls other Boeing accountable assets.
4. The assets product interfaces with other assets at Boeing.
5. Technical or program requirements for interface, fit-up, or structural
integrity warrant it, regardless of the above.
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4.3 Design/Definition Approval
A. Seller must obtain Design/Definition approval per Purchase Contract and/or
Supplier Statement Of Work for Special Tooling and Special Test Equipment
- BDS, BR&T, BT&E, BGS (Government Programs) (Ref. D33207-1) for any
initial asset engineering design/definition and/or revisions when:
1. Any Seller-defined design/definition for configuration critical assets
controlling Boeing accountable assets or product.
2. Seller owned asset is controlled by means of Purchase Contract provided
Boeing-defined asset engineering design/definition.
B. All initial asset designs/definition and revisions for assets used as Media of
Inspection (MOI) including any asset Inspection Media of product, used in
conjunction with production equipment and are considered “configuration
critical” assets requires design/definition approvals.
C. Any design/definition revisions of any asset used as Media of Inspection,
Assets Inspection Media of products, any asset used to control other assets or
any asset used in conjunction with production equipment affecting an assets
fit, form or function require approval. Typically includes Category I (CAT I),
Category II and any asset deemed configuration critical.
D. When required by Purchase Contract (Ref. section 1.2 General Requirements),
Boeing accountable assets require design/definition approvals for all
“configuration critical” assets used as Media of Inspection, Assets Inspection
Media of products, any asset used to control other assets or any asset used in
conjunction with production equipment.
E. The design/definition approvals must meet gated review process as outlined in
Gated Tool Design Record (X35200-2) or Seller equivalent gated process and
submitted to Boeing (ref. section 1.4 Seller Communication) using data
system (i.e., Supplier Data Requirements List (SDRL), Customer/Supplier
Data Transmittal (CSDT), and Integrated Data Management System (IDMS)
or the authorized secured transmittal platform (e.g. Message Courier) per
contractual instructions for approval.
F. The design/definition review process is considered complete when all aspects
and requirements of the asset design reviews are completed and signed off by
all Boeing stakeholders. This includes but is not limited to: Initial Concept
Concurrence, Functional Design Concurrence; Detail Tool Design
Concurrence, Fabrication Ready Design Approval; Tool Engineering
Complete.
G. Seller must maintain Gated Tool Design Record (X35200-2) or Seller
equivalent gated process documents as evidence of Boeing Design/Definition
approval.
H. Assets designs/definition not subject to Boeing approvals or gated reviews
include all other assets not defined above. Boeing reserves the right to
determine if asset design/definition approval is warranted during Purchase
Contract execution regardless of asset type.
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4.4 Design/Definition Requirements
A. All assets design/definition development requires a process plan/order/shop
traveler (work authorization) for all initial asset engineering
designs/definitions and any revisions. Work authorization may be provided by
Boeing or Seller.
B. All asset design or definition must meet the requirements as defined in a
Boeing approved Purchase Contract (Ref. section 1.2 General Requirements).
1. Seller developed asset designs/definition must be traceable to the product
engineering or specification criteria it was developed from.
C. All asset designs must be in English and the imperial measurement system.
Designs that are developed or maintained in foreign locations may include
their native language and measuring system to aide in the fabrication process.
D. All asset designs/definitions must meet D33011 series (Tooling Design
Standards) and American Society of Mechanical Engineers (ASME) Y14.100
requirements or a Seller’s equivalent design standards. All asset engineering
design/definition must meet requirements per American Society of
Mechanical Engineers (ASME) Y14.5 - Dimensioning and Tolerancing,
including Geometric Dimensioning and Tolerancing (GD&T).
1. Determination of a Seller's asset design/definition standards' equivalence
and capability will be at the discretion of Boeing (Ref. section 4.2 B).
E. When defined in Purchase Contract (Ref section 1.2 General Requirements)
that asset stress analysis is required by Boeing. All asset designs/definitions
must bear evidence of a formal stress analysis completion, traceability, and
acceptance (Ref. D33011-23).
F. When required by Purchase Contract (Ref section 1.2 General Requirements)
where asset definition (i.e. non-designed) is generated to define configuration
and fabrication of an asset, this definition is subject to all requirements listed
above. Boeing reserves the right for final determination of asset definition
development, approval and release. Typical data elements used or developed
for asset definition include, but are not limited to the following:
1. Released and configured product engineering (i.e. 3D Models, 2D
drawings).
2. 3D datasets (i.e. Supplier part files, Step files) including any dataset
variation used.
3. 2D data (i.e. mylar type layouts, flat pattern data) including any variation
used.
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5.0 Data Elements
5.1 Scope
This section applies to all Boeing and Government-owned assets. Data package
elements enable Boeing and Seller to identify, define, use, and periodically
inspect assets at Seller facilities.
5.2 Requirements
A. The following are data element requirements for asset identification,
engineering design/definition (e.g., drawings, models, digital data, etc.), usage
instructions, and inspection instructions. Based on any data element changes
to an asset, Seller must take any action necessary as defined by this document
to control and/or incorporate any contractual changes.
5.3 Asset Specification/Engineering Design/Definition Requirements
A. Seller must integrate and incorporate any asset specification and/or
engineering design/definition (Boeing or Seller-defined), original and revised
data elements, this includes any asset used as Media of Inspection, Assets
Inspection Media of products, any asset used to control other assets or any
asset used in conjunction with production equipment.
5.4 Asset Identification
A. Asset identification must meet Purchase Contract (Ref. section 1.2 General
Requirements).
B. Unless otherwise specified by Purchase Contract the asset identification and
changes must meet the requirements as defined in:
1. Tooling Assets - D33181-40 (Tool Identification); D33041 series (Tool
Identification Codes)
2. Special Test and Production Equipment – D33042-1(Boeing Special Test
Equipment, Agency Peculiar Property, and Plant Equipment
Identification),
C. Upon asset acceptance for production use or delivery, asset identification must
not be changed without notification and concurrence (ref. section 1.4 Seller
Communication).
5.5 Asset Usage Instructions
A. Asset usage instructions include technical and process related information for
asset users. They are typically provided when asset is highly complex, have
critical indexing methods, have multiple configuration settings, or when asset
usage cannot be easily communicated on the asset or within the manufacturing
work instructions. Asset usage instructions may include Original Equipment
Manufacturers (OEM) operation manuals typically provided for Equipment or
Special Test Equipment (STE).
1. Boeing-defined and provided
a. Seller must use and flow Boeing-provided asset usage instructions
including revisions to the asset users through Seller’s work
authorization methods. Seller must ensure and verify users are working
to latest asset usage instruction per active Purchase Contract.
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b. Seller requested asset usage instruction changes must be submitted
(ref. section 1.4 Seller Communication) for technical review and
approval prior to incorporation.
2. Seller-defined
a. Seller determination for asset usage instructions must meet the
requirements per section 4.2C3 (Asset Design/Definition). Asset
usage instructions including revisions must be flowed to the asset users
through Seller’s work authorization methods.
b. Seller must maintain a record of all Seller-defined asset usage
instructions, including revisions and must make them available to
Boeing upon request.
5.6 Periodic Inspection Plans
A. Seller must integrate and incorporate Boeing provided Periodic Inspection
Plans (PIP). Boeing provided Periodic Inspection Plans (PIP) must be
controlled, maintained and used per section 9.2 (Periodic Inspection) of this
document.
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6.0 Fabrication, Rework, and Modification
6.1 Scope
This section defines Seller requirements for asset initial fabrication, rework, and
modification.
6.2 Requirements
A. Seller must be deemed capable by Boeing prior to performing any asset initial
fabrication, rework, and modification. Capability determination will be
accomplished per section 2.0 (Seller Asset Capabilities).
B. Seller must maintain the following:
1. Documented information for asset fabrication, rework, and modification.
This includes any Seller capabilities used to realize, conform, configure,
or accept an asset.
2. Calibrated/Certified equipment, including Coordinate Measurement
Systems (CMS).
3. A trained/skilled workforce and maintain training records that include:
a. Process training.
b. Certified operator/processes (i.e., welding, nondestructive testing).
c. Equipment usage and proficiency (e.g., 3D applications, Coordinate
Measurement systems (CMS), etc.).
C. All assets require a work authorization (e.g., process plan, work order, tool
order, shop travelers, etc.) for any asset initial fabrication, rework, and
modification activities. Initial fabrication, rework, or modification work
authorization will be provided by Boeing or Seller. Seller’s work
authorization must be:
1. Traceable to Boeing Purchase Contract.
2. Traceable to asset Design/Definition and/or product engineering.
3. Traceable to asset fabrication specifications.
D. All asset initial fabrication, rework and modification documents must include
build log and/or inspection records (Ref. section 8.2 Acceptance).
1. When program specific forms are required per Purchase Contract, Seller
must contact Boeing (ref. section 1.4 Seller Communication) to obtain
clarification, instructions and any contractual forms.
2. Where program specific documented information is requested (e.g.
MAC1147 series forms, AS9102 forms, certifications, electronic reports),
Seller may develop and use equivalent documented information in lieu of
Boeing forms.
E. All assets must satisfy identification requirements as defined in section 5.4
(Asset Identification).
F. All initial fabrication, rework and modification records (i.e., work
authorization, inspection records, build log documents, electronic records
format), will be maintained per Seller Quality Management System (QMS)
and Section 19.0 (Records).
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6.3 Initial Fabrication, Rework and Modification
A. All assets must be initial fabricated, reworked, or modified as defined per
Purchase Contract (Ref. section 1.2 General Requirements) including
design/definition and/or specifications.
B. Where asset standards or specifications are defined (i.e., General notes, parts
lists, data elements, dataset, contract letter/memo, etc.) and are not available
Seller must immediately submit formal request (ref. section 1.4 Seller
Communication) for instructions and resolution.
C. Assets being initially fabricated, reworked, or modified using Product
Definition Template type layouts (e.g., electronically produced drawings,
engineering wash offs, master layouts, computer aided master layout, photo
contact master) as asset definition, all mylar type layouts must be maintained
per D950-11288-1 (Product Definition Template (PDT) Requirements,
Validation and Verification Processes, and Handling Instructions for Plot
Centers and Seller Use).
D. Any asset discrepancies identified that cannot be corrected during initial
fabrication, rework, or modification must be formally documented. Seller
must document discrepancies per section 15 (Nonconformance) and addressed
in accordance with Seller’s Quality Management System (QMS) process,
including Boeing notification.
6.4 Asset Material
A. No Material substitutions are allowed, including commercial off the shelf
(COTS) materials without prior, formal Boeing technical authorization. This
includes any asset initial fabrication, rework, and modification process where
safety of personnel, equipment and product can occur. Typical authorization
includes but is not limited to:
1. Seller submitted nonconformance (Ref. section 15 Nonconformance).
2. Boeing Material Substitution Drawing/Specification/List (i.e., D33181-
105 Tool Fabrication and/or Rework without Drawing Coverage).
6.5 Coordinate Measuring Systems (CMS) Measurement
A. Sellers using Coordinate Measuring Systems (CMS) for asset initial
fabrication, rework, and modification, must document and control their
processes in accordance with D6-51991(Quality Assurance Standard for
Digital Product Definition at Boeing Suppliers).
1. When using Coordinate Measuring Systems (CMS), measurements must
be performed within American Society of Mechanical Engineers (ASME)
Y14.5 paragraph 1.4 Fundamental Rules (l), unless otherwise specified.
All measured dimensions are applicable at 20°C (68°F). When
environmental conditions prevent control, material property Coefficient of
Thermal Expansion (CTE) must be used unless otherwise specified in
asset design/definition. Seller must contact (ref. section 1.4 Seller
Communication) for Boeing technical approval of any deviation.
B. Where Seller’s maintain a calibrated manual Coordinate Measuring Machine
(CMM) without model based measurement capability, Control of
Measurement Equipment compliance to D6-51991 (Quality Assurance
Standard for Digital Product Definition at Boeing Suppliers) is not mandatory.
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Seller’s using manual Coordinate Measurement Machines (CMM) for asset
measurement must maintain equipment certifications and user level
documented information, including results reporting and acceptance.
6.6 Master Coordination
A. As defined in Boeing Purchase Contract (Ref. section 1.2 General
Requirements) use of Category I (CAT I) master tools is mandatory. Where
physical or digital Category I (CAT I) master tools control asset features
(interface, interchangeability, etc.) is required, the Category I (CAT I) master
tool is the control authority regardless of design/definition values.
B. Usage and coordination criteria of Category I (CAT I) master tools as defined
on design/definition (general notes, fabrication specifications, etc.) must be
followed during initial fabrication, rework, modification, inspection or
periodic inspection of an asset.
C. Category I (CAT I) master tool coordination must be performed as defined per
asset design/ definition, including any control specification. Optimal
coordination must meet American Society of Mechanical Engineers (ASME)
Y14.5 paragraph 1.4 Fundamental Rules (l), unless otherwise specified and
per section 6.5 A1 (Coordinate Measuring Systems (CMS) measurements).
D. The Seller must ensure all Category I (CAT I) master tools are independently
coordinated to any asset where dimensional coordination integrity must be
maintained. Category I (CAT I) master tools must not be supported by any
asset features, framing or structures where clamping or weight forces will
influence coordination unless specifically defined in asset design/definition
(general notes, fabrication specification, etc.). Where physical Category I
(CAT I) master tools are coordinated to production tooling, the work must be
accomplished with proper attention to the temperature. Nominal temperature
range should be within 63 to 78 degrees F.
E. Unless otherwise contractually authorized the Seller must ensure Category I
(CAT I) master tool coordination is performed as a single event that verifies
and documents all critical features requiring coordination.
F. Seller will not use Category I (CAT I) master tool for direct manufacture of
production parts. Strict adherence to this requirement is mandatory.
G. The Seller must not rework or modify any Category I (CAT I) master tool
during possession or use. Any issues identified by Seller involving a Category
I (CAT I) master tool (i.e., configuration alignment, dimensional error,
damage, usage instructions,) must be formally documented per section 15
(Nonconformance) communicated to Boeing (ref. section 1.4 Seller
Communication) and/or documented per contractual requirements and Seller’s
Quality Management System (QMS).
H. The Seller must not use digital transfer of Category I (CAT I) master tool
coordination features where a physical master is required. Seller must not
deviate from Category I (CAT I) master tooling coordination as defined in
design/definition requirements. Any digital master process must satisfy
section 6.6 I & J.
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I. Sellers may request digital mapping/measurement of Category I (CAT I)
master tools. Seller must formally request technical authorization (Ref.
X30613 or Seller equivalent form) to digitally map/measure a Category I
(CAT I) master tool and obtain technical and contractual approval to proceed
(ref. section 1.4 Seller Communication).
J. Boeing contractually provided or as identified on asset design/definition,
approved replacement of physical Category I (CAT I) master tools with digital
configuration control datasets (digital masters) may be used for initial
fabrication, rework, modification, acceptance, and periodic inspection of an
asset.
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7.0 Special Processes
7.1 Scope
This section defines the special processes used during asset initial fabrication,
rework and modification involving materials modification, test / inspection in
accordance with established engineering specifications, drawings and quality
requirements.
7.2 Requirements
A. Sellers maintaining special process capabilities (i.e., material processing, heat
treating, plating, stress relief, welding) in support of asset fabrication must:
1. Maintain documented information to support special process capabilities.
2. Maintain facilities, certified and/or qualified equipment, and trained work
force in support of special process.
3. Use certified inspection personnel to the applicable American Society for
Nondestructive Testing (ASNT) Level or equivalent international industry
standard when required by Purchase Contract, specification and/or
engineering design/definition.
4. Maintain special process personnel training and certifications per
established Quality Management System (QMS) requirements.
B. Where Seller maintains Nadcap (National Aerospace and Defense Contractors
Accreditation Program) or accredited Certified Body special process
approvals, such approvals are recognized as special process capability
controls.
C. Sellers performing asset welding must meet requirements as defined in the
asset definition and/or fabrication standard during asset initial fabrication,
rework, or modification and satisfy all welding requirements per D32028
series.
D. All welders performing asset welding must meet and demonstrate proficiency
by qualifying to a recognized welding code or specification per D32028-1
(General Requirements for Tooling Welding).
E. During asset welding processes, all inspection level 1, 2A and 2B welds must
satisfy requirements per D32028-1 (General Requirements for Tooling
Welding) and/or AWS CWI/QC1 (American Weld Society Certified Weld
Inspector) or an equivalent international industry standard.
F. Special Process results must be documented and/or accepted on applicable
work authorization or certification report for processes performed as defined
per Quality Management System (QMS) and section 19.0 (Records).
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8.0 Acceptance
8.1 Scope
This section defines asset acceptance requirements for Seller and their
subcontractors for initial fabrication, receiving, relocation, rework, and
modification of Boeing accountable assets.
8.2 Requirements
A. Seller must demonstrate asset acceptance process capability and proficiency
(i.e., personnel, system capabilities, capacity). Seller must be deemed capable
(Ref. section 2.0 Seller Asset Capability) for asset inspection, verification,
validation when required to support Boeing Purchase Contracts (Ref. section
1.2 General Requirements).
B. Sellers must be deemed capable for use of Coordinate Measurement Systems
(CMS) for any asset acceptance processes and must be approved to D6-51991
(Quality Assurance Standard for Digital Product Definition at Boeing Sellers).
1. Best Fit alignments must not be used for asset acceptance unless
contractually authorized by purchase contract and/or Asset
Design/Definition. Evidence of authorization must accompany inspection
reports (Ref. section 19 Records Requirements). Seller must contact
Boeing (ref. section 1.4 Seller Communication) to obtain authorization
and technical instructions when Best Fit alignment is needed or requested.
C. Sellers must be deemed capable for use of manual Coordinate Measurement
Machines (CMM) for asset acceptance processes as defined per Seller’s
Quality Management System (QMS). Including equipment certifications, user
level documented information, results reporting and acceptance.
D. It is the Seller’s responsibility to ensure asset meets Boeing Purchase
Contract, design/definition, and any specifications to satisfy compliance and
configuration alignment.
E. All assets initial fabrication, rework and modification by Seller must be 100%
inspected. All acceptance results must bear evidence of acceptance by
qualified personnel. This includes any Seller generated inspection media (i.e.,
graphic, sketches, mylar type layouts) being used to accept an asset including
any asset features, details or assemblies.
F. All assets require a fabrication inspection record or build log (Ref. section 6.2
Fabrication, Rework, and Modification). Records will indicate fabrication
and/or inspection status of both in-process (progressive) and final inspection
and acceptance of an asset. Seller is responsible for using any requested
inspection record or build log forms or electronic acceptance records format
(Ref. section 19.0 Records) or equivalent Seller forms for all initial
fabrication, rework, or modification acceptance. When program specific forms
are required per Purchase Contracts, Seller must contact Boeing (ref. section
1.4 Seller Communication) to obtain clarification, instructions and any
contractual forms.
G. Before final acceptance of an asset, the Seller must:
1. Review the asset inspection records (i.e., inspection record, build log,
work authorization), for completeness and accuracy, making sure all
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required dimensions and build specifications are recorded, accepted by
qualified personnel, and dated.
2. Verify that asset and all loose and removable parts are identified.
3. Ensure that all asset critical tolerances of +/- 0.015” or less are
documented on build and/or inspection records as defined on asset
design/definition.
4. Ensure all Geometric Dimensioning and Tolerancing (GD&T) features,
regardless of tolerance, are documented on inspection records or build
logs as defined on asset design/definition. (Ref. American Society of
Mechanical Engineers (ASME) Y14.5).
5. Ensure all fabrication special processes (e.g., material, heat treat, plating,
welding etc.) and general notes are documented including any industry
certifications as applicable.
H. All asset inspection records or build logs must be retained and made available
upon request or provided as required per Purchase Contract requirement as
defined in section 19.0 (Records). Seller must formally notify Boeing (ref.
section 1.4 Seller Communication) for all issues involving development,
submittal and retention of asset acceptance records.
I. Boeing reserves the right to verify asset setup and asset acceptance including
Category I (CAT I) master coordination per section 6.6 (Master
Coordination). When Boeing verification of asset is identified to support
Boeing Purchase Contracts (Ref. section 1.2 General Requirements), Seller
must contact Boeing (ref. section 1.4 Seller Communication) to coordinate
Boeing attendance.
J. When Boeing asset acceptance is required by Boeing Purchase Contract (Ref.
section 1.2 General Requirements), Seller must notify Boeing (ref. section 1.4
Seller Communication) or process request within Boeing’s Quality data
system when Seller is ready for Boeing asset acceptance. Seller must only
complete asset acceptance requirement per section 8.2 G prior to requesting
Boeing asset acceptance support. Seller must be directly available to assist
Boeing during asset acceptance when required.
K. Seller must apply visible acceptance evidence of an asset by one of the
following methods:
1. Physically on ST by permanent means such as impression stamping,
chemical or mechanical etch, laser or machine engraving, etc.
2. A documented alternate method containing the following characteristics
when asset size, usage and environment does not permit physical evidence
marking (e.g., identification tags, unique identifier – color, marking, etc.).
Ref section 5.6 Asset Identification.
3. As defined per Boeing contractual instructions or as defined per Seller’s
Quality Management System.
8.3 Asset Acceptance Methods
A. Seller must apply one of the following asset acceptance types:
1. Minor Verification: The most common process. Typically occurs when
manufacturing uses a new, reworked or modified asset for the first time as
defined in manufacturing work instructions (shop traveler, etc.). During
first production run manufacturing work instructions must clearly define
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independent product verification method and sequence to determine asset
acceptance status.
Typically applied to low-risk assets of basic to moderate complexity and
may or may not control product configuration. The asset is
unconditionally released for production use upon completion of tool
fabrication and acceptance. The initial result of product from the asset is
independently verified to validate the asset produces compliant product or
test per engineering requirements and/or specifications. Successful
completion of asset minor verification allows asset acceptance per section
8 (Acceptance). Should asset users encounter issues or nonconforming
conditions, the Seller’s documented asset support process applies.
2. Major Verification – Product Fabrication: Process applied to assets that
are defined and/or fabricated with intentional compensation from product
nominal engineering definition to accommodate manufacturing usage or
material processing phenomena such as spring back or thermal behaviors.
The asset is typically fabricated to design/definition requirements,
accepted, and conditionally released for manufacturing use. During first
production run manufacturing work instructions must clearly define
independent product verification method and sequence to determine asset
acceptance status. The initial product of the asset is independently verified
to validate the asset produces compliant product or test per engineering
requirements and/or specifications. Successful completion of asset Major
Verification – Product Fabrication allows asset acceptance per section 8
(Acceptance). Once accepted the asset is unconditionally released for
production use.
3. Major Verification - Assembly: Process typically applied to complex
assets, including end item assets used as Media of Inspection (MOI) and
any asset Inspection Media of product. Typically consists of streamlined
forms for collecting issues identified during initial use and inspections. As
a rule assets are initially fabricated, reworked and modified to
design/definition requirements, including Category I (CAT I) Master
Coordination and accepted per asset work authorization documents. Asset
is conditionally released for manufacturing and assembly use (e.g., proof
for production). Verification schedule may include more than one usage to
verify stability and dimensional integrity when an asset produces, verifies,
or tests a part or assembly to product engineering requirements. Asset
periodic inspections per section 9 (Periodic Inspection) may be conducted
after production assemblies are produced to demonstrate asset stability and
dimensional integrity (typically applied to very large assembly jigs, check
fixtures and test stands that may experience foundation settling, base and
end-gate settling, etc.). Successful completion of asset Major Verification
- Assembly allows asset acceptance per section 8 (Acceptance). Once
accepted the asset is unconditionally released for production use.
B. Boeing reserves the right to determine the asset acceptance method. Should
Seller have questions regarding selecting the appropriate asset acceptance
method, formally contact Boeing (ref. section 1.4 Seller Communication) to
obtain technical instructions for resolution.
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C. During asset acceptance, asset must be inspected in an unrestrained condition
“free state” regardless of acceptance method, system or equipment used unless
otherwise specified in design/definition or specification.
1. When defined asset acceptance in restrained condition is determined,
acceptance typically as a result of assets intended usage and may include:
a. Where the asset is used in restrained condition (e.g., mill fixtures).
b. Where asset is restrained (clamped in place) to production hardware or
structure during usage (e.g., trim templates, drill plates).
2. Unrestrained asset acceptance typically includes:
a. Standalone assets where product is installed or attached for use,
acceptance or test (e.g., check fixtures, assembly jigs, test stands).
b. Asset plumb and leveling to meet design, specification and reference
system requirements is not considered restrained (e.g., eliminate
rack/sag/twist conditions).
c. Category I (CAT I) master tools are rigged/indexed/coordinated in an
independent unrestrained condition during any fabrication or
acceptance process per section 6.6 (Master Coordination).
8.4 Proof Load Test
A. When required by Boeing Purchase Contract (Ref. section 1.2 General
Requirements), that Proof Load Test must be completed, documented, and
accepted by the Seller or Seller’s approved subcontractor per section 1.3
(Subcontractor General Requirements).
B. Boeing reserves the right to witness the proof load test. When required Seller
must notify Boeing (ref. section 1.4 Seller Communication) or process request
within Boeing’s Quality data system when Seller is ready for Boeing witness
of proof load test activities.
C. All proof load test activities must meet requirements as identified in asset
design/definition (e.g., sheets, diagrams, cases, graphics, etc.) and any proof
load test specifications per Purchase Contract or design/definition general
notes.
D. Seller must use certified equipment/devices (load cells, scales, weights, torque
wrench, etc.) when performing proof load testing.
E. Seller must affix or provide any required proof load test labels or tags when
required by Purchase Contract, design/definition or specification.
F. When Seller is contractually delegated proof load test activity, Seller must
perform proof load test per design/definition and document results per section
8.2 D and E (Acceptance).
G. The Seller must develop a separate proof load test certificate for each asset
requiring proof load testing. Each Proof load test certification must be
traceable to Purchase Contract, asset, asset design/definition, and asset
configuration. Proof load test results and certification must be processed per
section 19 (Records).
H. Seller must contact Boeing (ref. section 1.4 Seller Communication) for
technical instructions when proof load test requirements are not defined, such
as but not limited to, Boeing witness, proof load test duration, rigging, rated
loads, objective evidence, reports, results submittal, etc.
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9.0 Periodic Inspection
9.1 Scope
This section defines the requirements for assets that require periodic inspection.
Any asset being used as control media or the only means to accept, test and
determine asset configuration is subject to periodic inspections. Typically assets
subject to periodic inspection supports end item assets, including Major End-Item
assembly assets for conformance and configuration to contracted engineering
design/definition.
9.2 Requirements
A. Seller must demonstrate Periodic Inspection process and system capability
and proficiency (i.e., personnel, system capabilities, capacity). Seller must be
deemed capable (Ref. section 2.0 Seller Asset Capability) for asset Periodic
Inspection when required to support Boeing Purchase Contracts.
B. When required by Boeing Purchase Contract (Ref. section 1.2 General
Requirements), asset design/definition or any asset used as control media or
for product acceptance, including Boeing identified Major End-Item assembly
assets are subject to Periodic Inspections. All Periodic Inspection actions will
be accomplished as defined below.
C. Any asset being used as control media in verifying product features or
characteristics of parts or assemblies requires periodic inspections in addition
to each use condition checks (ref section 10 – Each Use Condition Check).
This includes any asset deemed Media of Inspection (MOI) or Inspection
Media of product by Seller or Boeing. Asset types subject to Periodic
Inspection include but are not limited to the following:
1. Special Tooling (ST) – Category II (CAT II)
2. Major End-Item Assembly Special Tooling (ST) – Category II (CAT II)
3. Special Test Equipment (STE)
4. Any asset deemed configuration critical by Boeing
5. Production Equipment
D. There are two specifically defined types of asset periodic inspections. Type 1
(Major) and Type 2 (Minor) for Media of Inspection (MOI) and Inspection
Media of Product assets.
1. Type 1 (Major) – Periodic Inspection Requirement: Physical dimensional
measurement and/or coordination to a Category I (CAT I) master tool
(physical or digital) including visual inspection that must be documented
on a prescribed Periodic Inspection Plan (PIP) at a periodic interval or
frequency.
2. Type 2 (Minor) – Periodic Inspection Requirement: Visual inspection that
must be controlled by documented information or on a prescribed Periodic
Inspection Plan (PIP) at a periodic interval or frequency.
E. Seller must maintain a listing (e.g., metrology recall system, gage control
application, spread sheet, etc.) of all assets being used as Media of Inspection
(MOI) or Inspection Media of product by Seller, including any asset provided
to a subcontractor. These assets being used to accept Boeing or Government
products must include the following:
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1. Boeing and Government accountable assets supplied by Boeing.
2. Boeing and Government accountable assets provided by a Seller.
3. Seller accountable assets controlled by Boeing provided
Design/Definition.
4. Any assets deemed configuration critical by Boeing.
E. When Seller has demonstrated capability to Boeing to perform periodic
inspections, the following requirements must apply:
1. Seller may determine asset for use as Media of Inspection (MOI) or
Inspection Media of product by Seller owned and Boeing accountable
asset (i.e., category III special tools). Seller’s process for asset product
acceptance determination must meet the following conditions:
a. Seller retains/maintains asset engineering design/definition.
b. Seller retains Product engineering definition to determine independent
product verification.
2. For Seller’s initial asset determination all assets must meet asset
acceptance requirements per section 8.2 (Acceptance) or have evidence of
acceptance (i.e., physical acceptance stamp, etc.).
3. After initial asset product acceptance determination Periodic Inspection
Type 1 or Type 2 with supporting Periodic Inspection Plan (PIP) must be
implemented based upon product engineering and asset complexity.
4. Seller determination of asset Production acceptance (i.e., category III)
status must be controlled per section 9 (Periodic Inspection).
F. Boeing reserves the right to initiate changes to any asset Periodic Inspection
designation regardless of asset type or category. Seller-initiated changes to the
asset periodic inspection designation or periodic inspection frequency or
interval must be approved by Boeing (ref. section 1.4 Seller Communication)
prior to implementation.
G. At a minimum, Seller must conduct periodic inspections every 12 months for
all assets in use until sufficient data is available to adjust the frequency of
periodic inspection.
H. Seller must review the interval of periodic inspections for adequacy and adjust
intervals accordingly. Increasing or decreasing the interval must be
accomplished using statistical methods and historical periodic inspection data.
I. If Seller is unable to perform Periodic Inspection at designated frequency due
to production constraints or spares requirement, Seller must formally request
Periodic Inspection extension from Boeing (ref. section 1.4 Seller
Communication) prior to Periodic Inspection expiration. Sellers must provide
extension justification and estimated Periodic Inspection
performance/completion date.
J. Any asset that exceeds Periodic Inspection frequency date, including customer
rejection of asset Periodic Inspection extension, must be documented per
section 15 (Nonconformance) and processed per Seller’s
Quality Manage System (QMS) process. Any asset as a result of delinquent
Periodic Inspection may not be used for product acceptance until such time as
the asset Periodic Inspection is completed and accepted. Alternate asset usage
and verification methods may be required per section 15.2 H&I
(Nonconforming Asset).
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K. Seller must apply an easily recognizable indication (e.g., label, tag, etc.) to the
asset that bears the expiration date, acceptance status, and inspection authority
of the individual applying the indicator.
L. Seller must provide and maintain the results of preceding and current periodic
inspection of assets. Periodic Inspection result must be controlled per section
19 (Records). The records must include at a minimum:
1. Dimensions/features verified during the periodic inspection as defined in
Periodic Inspection Plan (PIP), including actual values from coordination
to Category I (CAT I) masters.
2. The date of the periodic check.
3. The inspection authority of the individual who performed the check.
4. The date of the next scheduled periodic check (expiration date).
5. Asset engineering design/definition used as inspection requirement.
6. Verification of configuration level.
7. Identification of the acceptance status of the asset.
8. Traceability to Periodic Inspection Plan (PIP) and revision.
M. All assets supporting active procurement including out of production spares
procurement must maintain current periodic recall status.
1. Assets supporting recurring program procurement must maintain current
periodic tool inspection recall regardless of asset status (i.e., stored, in-
active)
2. For assets supporting out of production (i.e., spares) procurement greater
than one year, the periodic recall may be extended until such time as asset
status changes due to additional procurement activity.
3. Assets exceeding exception status of one year must be submitted as excess
and processed per Purchase Contract close-out requirements.
4. For assets (stored, in-active, etc.) under periodic inspection extension
status, assets must satisfy completed Periodic Inspection (Type 1 or Type
2) prior to next usage.
9.3 Periodic Inspection Plans
A. Seller must create documented information to develop and maintain Periodic
Inspection Plans (PIP). This process must:
1. Be traceable to individual specific asset.
2. Be traceable to design/definition.
3. Contain asset specific inspection instructions, including visual inspection.
4. Be maintained under configuration controls.
5. Be approved and released.
B. The Seller will create Periodic Inspection Plans (PIP) that are individual
“asset specific” plans that supports asset assigned periodic inspection
frequencies. Periodic Inspection Plans (PIP) are intended to provide inspection
instructions to asset users required to maintain asset conformance and
configuration. The use of approved text and graphics to enhance the Periodic
Inspection Plan (PIP) content and usage is encouraged.
C. Periodic Inspection instructions are typically developed and used for Special
Tooling (ST) Category II (CAT II) Type 1 (Major) and Type 2 (Minor);
Special Test Equipment (STE); and Equipment. Including Boeing identified
Major End-Item Assembly Category II (CAT II) Type 1 (Major) assets.
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1. Seller-defined
a. Seller-defined asset Periodic Inspection Plans (PIP) for all Category II
(Cat II) Type 1 (Major) periodic inspection instructions, including any
Major End-Item Assembly assets must be submitted to Boeing for
technical approval. This includes any Boeing-defined Periodic
Inspection Plans (PIP) revised or changed by Seller.
b. Seller must submit Seller-defined Periodic Inspection Plans (PIP),
including changes to Boeing (ref. section 1.4 Seller Communication)
for technical approval.
c. Seller must maintain configuration alignment of all Periodic Inspection
Plans (PIP) to design/definition.
2. Boeing-defined
a. Seller requested changes to Boeing-defined Periodic Inspection Plans
(PIP) must be submitted to Boeing for technical approval (i.e.,
configuration alignment, inspection instructions, or frequency).
b. For Boeing provided assets identified as Media of Inspection (MOI),
Inspection Media, or Major End-Item Assembly asset of product
where no Periodic Inspection Plan is provided Seller must notify
Boeing (ref. section 1.4 Seller Communication) for technical
instructions to receive or develop Periodic Inspection Plans (PIP).
D. Periodic Inspection instructions must include:
1. Type 1 (Major) dimensional inspection - Design/Definition requirements
to verify all asset features being used to control product
compliance/acceptance including but not limited to: locators, indexes,
surfaces, details, pins, bushings, reference systems, enhanced reference
systems (ERS), datum’s, adjustable datum’s, tooling holes, gages, fittings,
adaptors, etc. and Each Use Condition Check elements as defined per
section 10 (Each Use Condition Checks). Instructions must include all
critical tolerance ranges and Geometric Dimensioning and Tolerancing
(GD&T) features.
a. Where Category I (CAT I) master tools (digital or physical) are asset
authority and are required as part of Periodic Inspection instructions to
verify an asset section 6.6 (Master Coordination) and section 8.3
(Inspection Method) apply.
2. Type 2 (Minor) visual inspection – defined features and all elements per
section 10 (Each Use Condition Check).
E. The following must be included as part of Asset Periodic Inspection Plan:
1. Periodic Inspection Plan (PIP) traceability (name or number) and revision
2. Code/Number of the asset.
3. Serial Number (when applicable).
4. Unit Number
5. Detail and Part Accountable
6. Foreign Object Damage (FOD) check
7. Operation and Function
F. At a minimum, Seller must initiate Periodic Inspection Plans (PIP) on
approved Seller work authorization for any Type I (Major) Periodic
Inspection. Seller must flow Periodic Inspection Plans (PIP) to users
performing periodic inspection activity.
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G. Any discrepancies identified during asset Periodic Inspection must be
properly documented per Seller’s Quality Management System (QMS) as
defined per section 15 (Nonconformance) including Boeing notification.
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10.0 Each Use Condition Check
10.1 Scope
This section applies to Sellers using accountable assets as defined in work
authorization documents. Any accountable asset being used during manufacturing
of Boeing products is subject to Each Use Condition Checks.
10.2 Requirements
A. Sellers must maintain documented information to perform Each Use
Condition Checks for all Boeing accountable assets, government and seller
assets accountable to Boeing. This includes any Boeing provided asset data
elements controlling configuration of seller owned assets.
B. Seller Each Use Condition Check documented information must at a
minimum address the following:
1. User actions and communication instructions.
2. Roles and responsibilities.
3. Asset segregation and resolution process.
C. The user (asset coordinators, operators, mechanics, fabricators, etc.) of an
asset is required to perform, at a minimum, a visual validation of the asset
before each usage. This includes any mechanical handling equipment used to
move or lift product or an asset. Typical areas of consideration during Each
Use Condition Check include, but are not limited to the following:
1. Asset is properly identified and identification is legible as defined in Seller
work authorization (shop traveler, work order, etc.)
2. An asset has evidence of acceptance on or near asset identification.
3. The asset configuration level is identified.
4. Asset instructions, directions, and caution/safety tags are securely attached
or available and legible when used.
5. All asset details/parts are available and in good condition:
a. “L” pins, hand knobs, scribes, step pins, etc. are attached to asset and
are functional.
b. Rubber cushions and protective pads are functional and secure.
c. Toggle clamps, straps, and other hold-down devices are functional.
d. There are no worn, loose, cracked, or missing bushings.
e. There is no evidence of mushroom, damaged edges, or surfaces on
details part or assembly locating features.
f. There is no corrosion or contamination on any part/assembly locating
features.
g. Asset construction is complete. No missing nuts, bolts, washers, dowel
pins, etc. preventing assets intended use. Including clear unauthorized
use of spacers, washers or shims.
6. Drill indicators, index holes, and surface stamping are clear and legible.
7. There is no obvious degradation of tamperproof measures.
8. No expired dates on asset certification labels (Periodic Inspection,
Calibration, Preventative Maintenance and Proof Load test labels). This
includes any gages, read-outs, etc. with a certification label used as part of
an asset.
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D. All Users and/or asset coordinators must ensure assets function correctly and
is properly maintained per section 13.0 (Preventive Maintenance).
E. Seller must maintain formal objective evidence of Each Use Condition Checks
being performed prior to use. Objective evidence may include operator
acceptance sequence within manufacturing planning, etc.
F. The asset must only be used for the specific purpose for which it was
intended.
G. Any asset discrepancies found during Each Use Condition Check must be
properly documented and addressed in accordance with Seller’s Quality
Management System (QMS) including asset maintenance process.
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11.0 Manufacturing Work Instructions
11.1 Scope
This section covers all categories of Boeing or Government assets accountable to
Boeing involved with the manufacture of Boeing or Government products. It
defines Seller requirements for Seller manufacturing work authorization
documents that require the use of assets.
11.2 Requirements
A. Seller must ensure any asset used for the manufacture of Boeing products is
documented and/or identified on appropriate Seller’s and its subcontractors’
manufacturing work authorization documents (shop travelers, work orders,
manufacturing plans, etc.).
B. Where asset traceability is identified on work authorization documents, asset
usage instructions may be included as part of operation sequence or
coordination data where asset usage instructions can be easily communicated.
C. When separate approved asset usage instructions exist, Seller must document
and/or identify the asset usage instruction, in addition to listing the asset in the
work authorization document and make them available to all asset users.
D. Seller must ensure assets are used in accordance with Seller work
authorization documents as required per Boeing contractual requirements.
E. When compliance issues or Seller manufacturing methods and processes come
into conflict with the asset engineering design/definition, Seller work
authorization documents, asset usage instructions, or asset configuration
alignment Ref. section 1.2 (General Requirements), Seller is required to
follow its Quality Management System (QMS) for nonconformance reporting
and coordinate with Boeing (ref. section 1.4 Seller Communication) to obtain
technical instructions for resolution.
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12.0 Production Process Verification and Asset Relationship
12.1 Scope
This section covers Boeing accountable and Government owned assets as related
to Production Process Verification as defined in AS9100, also referred to as First
Article Inspection (FAI) as defined in AS9102. The Production Process
Verification requirements are in effect even after initial asset acceptance.
12.2 Requirements
A. All assets used during the performance of Production Process Verification
activities must show evidence of acceptance status (Ref. section 8.2K
Acceptance) prior to use, including assets used for product acceptance.
B. The following asset-related events must require a partial or complete re-
accomplishment of a Product Process Verification activity for the subject part
or assembly when:
1. Asset engineering Design/Definition changes potentially affecting fit,
form or function occur, including asset coded Numerical Controlled (N/C)
program changes of parts or assemblies.
2. Manufacturing changes to asset configuration controlling or verifying
features potentially affecting fit, form, or function of the product.
3. Natural or man-made disaster (e.g., earthquake, flood, and tornado) where
asset is potentially affected (Ref. section 13 Preventive Maintenance).
C. Asset related events that do not invoke re-accomplishment of Product Process
Verification include the following:
1. Asset Preventive Maintenance per section 13 (e.g., cleaning, dressing
index features, replacement of pins, etc.).
2. Returning asset to previously accepted design/definition configuration.
3. Asset design/definition revisions or modifications to asset features not
affecting configuration of part or assembly (e.g., lightening holes,
clearance issues, operator access issues, etc.).
12.3 Communication Requirements
A. When Boeing initiates actions that require a partial or complete re-
accomplishment of Product Process Validation due to asset-related events,
Seller is required to communicate the requirement to any affected Seller’s
subcontractors.
B. When Seller initiates actions that require a partial or complete re-
accomplishment of Product Process Validation due to asset-related events,
Seller must notify Boeing prior to implementation. Boeing
determination/approval and coordination of appropriate Product Process
Verification actions is required.
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13.0 Preventive Maintenance
13.1 Scope
This section covers the scope of asset user maintenance and preventive
maintenance, which includes all Boeing-accountable and Government owned
Boeing accountable assets in Seller’s and its subcontractors’ possession. Normal
asset wear is expected during use, and user and preventive maintenance is
expected.
13.2 Requirements
A. Sellers must maintain documented information with clear roles and
responsibilities to perform user maintenance and preventive maintenance,
including development and control of Preventive Maintenance Plans (PMP),
for all Boeing accountable assets, government and seller assets accountable to
Boeing.
1. User Maintenance – Typically preformed prior to and during asset usage
by the asset user.
2. Preventive Maintenance – Typically performed by asset coordinators or
maintenance personnel as defined by a Preventative Maintenance Plan
(PMP) on a prescribed frequency or schedule.
B. Where a prescribed Preventive Maintenance frequency or schedule is defined
Seller must maintain an asset listing (e.g., recall system, gage control
application, spread sheet, etc.) and retain evidence of Preventive Maintenance
events, results and completion.
C. Asset features may become damaged or lost during normal usage (e.g., pins,
clips, clamps, pads, removable components, etc.). Seller is responsible to
establish and maintain a process to minimize damage or loss, and take actions
to repair, or replace damaged or lost asset features.
D. Sellers and Seller’s subcontractors are required to keep all assets in a
serviceable condition.
E. Seller must take appropriate actions per Quality Management System (QMS)
to address assets with excessive wear, damage or no longer in a serviceable
condition. This may include Boeing notifications, nonconformance reporting
(ref section 15), work authorization (Ref. section 6).
F. Unless otherwise specified in the Purchase Contract (Ref. section 1.2 General
Requirements), Seller is only responsible for repair to assets resulting from
wear, damage during usage, or inappropriate protection and storage. Any
deviation or exceptions will be subject to negotiation between Boeing (ref.
section 1.4 Seller Communication) and Seller.
G. Any asset discrepancies found during preventive maintenance activity must be
properly documented and addressed in accordance with Seller’s Quality
Management System (QMS).
H. Seller must immediately and formally submit technical request to Boeing (ref.
section 1.4 Seller Communication) for resolution when normal wear or
nonconformance conditions exceed Seller capability for correction (ref section
2 Seller Asset Capability and section 1.3 Subcontractor General
Requirements).
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I. Seller must, in a timely manner, disclose and formally submit request to
Boeing (ref. section 1.4 Seller Communication) for technical solution when
asset approaches end of useful life cycle to ensure resolution is addressed
before impact to the product quality or deliveries occur.
J. Any assets deemed Configuration Critical, Media of Inspection (MOI) or
Inspection Media of product by Seller or Boeing that has been subjected to a
natural or man-made incident such as:
1. An earthquake of magnitude 5.0 or higher on the Richter scale (or
equivalent) within a 50 mile radius.
2. A natural disaster (hurricane/cyclone, flood, tornado, etc.).
3. Man-made incident.
Where an incident may affect stability, integrity or conformity of an asset,
regardless of category or type, at a minimum asset must be validated.
Validation may include Each Use Condition Check (ref section 10), re-
accomplishment of Periodic Inspection (Ref. section 9) or verification to
design/definition requirements depending upon severity of the incident. Seller
should contact Boeing (ref. section 1.4 Seller Communication) for guidance
when necessary.
13.3 User Maintenance
A. The basic elements of asset user maintenance are Each Use Condition Checks
(Ref. section 10) and Periodic Inspections (Ref. section 9).
B. Seller must monitor asset features for excessive wear during use and take
actions to address worn assets before the asset becomes nonconforming to
asset design/definition requirements or produces a nonconforming product.
C. At a minimum, Seller must place special emphasis on asset used in situations
that may subject the asset to excessive wear or damage. These situations
include but are not limited to:
1. Exposure to cutting (e.g., routing, drilling, reaming) cycles.
2. Exposure to force and load cycles.
3. Exposure to vibration, striking, or impact cycles.
4. Exposure to thermal cycles.
5. Exposure to chemicals and fluids.
6. Exposure to corrosive environment.
D. Any maintenance issue identified by the user during asset use must be
communicated and addressed by Seller’s Quality Management System
(QMS).
13.4 Preventive Maintenance
A. Assets subject to Preventive Maintenance must have a documented Preventive
Maintenance Plan (PMP) and approved by Seller at a minimum. The
Preventive Maintenance Plan may be Seller developed or provided by Boeing
in support of Purchase Contracts.
B. Preventive Maintenance Plan (PMP) must provide scheduled inspection,
maintenance, and functionality test instructions as required to maintain the
asset. These instructions are intended to minimize asset malfunction due to
wear and neglect, and reduce risk of asset producing a nonconforming
condition.
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C. Typically required for any assets with special systems, load bearing
equipment (static or overhead) or assets subjected to sustained usage. These
assets typically include but are not limited to the following:
1. Production Equipment – Automated machines and devices, including
qualified Computer Numerical Control (CNC) machines.
2. Handling Equipment – Below the Hook and transport devices used to
move product or articles (Proof Load Test).
3. Special Test Equipment (STE) – Includes special systems (pneumatic,
hydraulic, electrical, and/or software)
4. Equipment used in conjunction with Special Tooling (ST) – Automated
machines (spar mills with mill fixtures, Rivet machines with holding
fixtures, etc.).
D. Assets subject to Preventive Maintenance are required to have asset
maintenance actions/instructions at a prescribed interval or frequency.
Preventive Maintenance Plans (PMP) may include:
1. Original Equipment Manufacturers (OEM) maintenance instructions.
2. Asset design/definition maintenance requirements.
3. Purchase Contract (Ref. section 1.2 General Requirements) maintenance
instructions.
E. There are typically three levels of Planned Preventive Maintenance events
performed by qualified personnel.
1. A visual condition check of asset in using condition.
2. A visual condition check, cleaning, lubricating, and adjusting of items
such as nut, bolts, machine ways/lead screws, safety devises, handles, etc.
and functionality checks such as wheels, casters, motors, lead screws,
hoists, rails and bearings.
3. Asset disassembly, visual inspection, functional testing, non-destructive
inspection (NDI), or software testing/certification. This level of
Preventative Maintenance normally requires work authorization (shop
traveler or work order), and acceptance by Quality or qualified personnel.
F. Seller developed Preventive Maintenance Plans must include, at a minimum
the following:
1. Unique Preventive Maintenance Plan identification (number, etc.).
2. Configuration control.
3. Release status.
4. Frequency/schedule as required.
5. Asset maintenance instructions, including OEM manual if required.
6. Maintenance instruction alignment to asset design/definition features.
G. Records of current and previous asset Preventive Maintenance events must be
maintained per section 19 (Records).
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14.0 Protection and Storage
14.1 Scope
This requirement is applicable to all Boeing-accountable and Government owned
Boeing accountable assets in Seller’s and its subcontractors’ possession. This
requirement is applicable to all assets in use, not in use or stored.
14.2 Requirements
A. All assets, regardless of category, must be protected to prevent loss, theft,
damage, and deterioration while in the possession of Seller or Seller’s
subcontractor.
B. Assets in Seller’s possession must be protected from undue damage and
deterioration including inappropriate exposure to the elements. When
required, assets will have an appropriate preservative applied to prevent
corrosion or oxidization.
14.3 Asset in Use
A. Prior to each use, users must review the asset usage instructions and perform
Each Use Condition Check (Ref. section 10) for serviceable condition. Any
conditions hindering fit, form, function, or tool performance must be
addressed through Seller’s asset maintenance process (ref section 13.2) up to
possible nonconformance documentation (Ref. section 15.2).
B. Seller must review the asset documentation (design/definition, Original
Equipment Manual (OEM), usage instructions, etc.) for serviceable condition
and functionality. Any conditions hindering fit, form or function must be
addressed through Seller’s maintenance process, up to documenting a
nonconformance. (Reference section 13 Preventive Maintenance)
C. When assets are maintained (stored) in manufacturing areas to support
recurring production, seller is required to protect asset to prevent corrosion or
oxidization which may include application of an appropriate preservative.
14.4 Asset not in Use
A. Asset not in use or stored by Seller must be controlled in a fashion and in
facilities to prevent loss, theft, damage, and deterioration. Measures must be
taken to apply an appropriate preservative and to protect assets from the
elements. Seller’s storage requirements must include periodic preservation /
condition checks for all assets in storage.
B. As a result of procurement completion or Purchase Contract termination
involving an asset, such assets deemed out of production, stored or inactive
must be properly documented within the supplier accountability process (Ref.
E000 Supplier Requirements for Buyer/Government/Customer Property
Management and D33113-1 Accountability of In-Plant/Out-Plant Special
(Contract) Tools). Seller must, in a timely manner, formally notify Boeing
(ref. section 1.4 Seller Communication per Purchase Contract closeout process
and/or submit through online data system a request for asset disposition,
regardless of asset type. (e.g., customer return, Buyer’s request for seller
storage, etc.)
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14.5 Storage and Protection Requirements
A. This requirement is applicable to all Boeing owned and Government owned
Boeing accountable assets in Seller’s facilities, including interdivisions or
subcontractors’ possession. The Seller must utilize the storage requirements
described below for the purpose of asset storage.
B. Where Seller maintains a Government approved accountability system, Seller
must follow Government property controls for storage of all Government
owned assets provided in support of a Boeing Purchase Contract, including
any additional storage requirements of this document where applicable.
C. When required by Purchase Contract Seller must follow requirements of E000
(Supplier Requirements for Buyer/Government/Customer Property
Management and D33113-1 (Accountability of In-Plant/Out-Plant Special
(Contract) Tools) for any Boeing accountable asset and Government owned
asset accountable to Boeing being stored by Seller.
D. Asset storage and preservation will be negotiated between the seller and
Boeing (ref. section 1.4 Seller Communication) per the affected Boeing
division as defined by Purchase Contract.
E. Assets deemed out of production, stored, inactive, or have reached the end of
procurement or Purchase Contract termination, must be properly documented
within the Seller accountability system.
F. Seller must formally notify Boeing (ref. section 1.4 Seller Communication)
for contractual instructions to disposition assets upon end of production or
Purchase contract closeout (e.g., return, Boeing’s request for Seller storage,
etc.).
G. Assets must be accounted for and stored in a manner to prevent loss, theft,
damage, and deterioration. Seller must not expose Category I (CAT I) Master
Tool or Master Tools containers to the outside environment.
H. For all assets in storage Seller must perform periodic preservation / condition
checks. Preservation checks at a minimum must include:
1. Accountability – Identification and asset stored in documented location.
2. Condition check - ensure an appropriate preservative is applied to prevent
corrosion or oxidization.
3. Resolve storage issues – restore or rehabilitate asset where corrosion,
oxidization or environmental issues have occurred. (Ref. section 13.2
Preventive Maintenance).
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15.0 Nonconformance
15.1 Scope
This section covers all categories or types of Boeing accountable and Government
owned assets accountable to Boeing involved with the manufacture of Boeing or
Government products. It defines requirements for Seller’s formal documentation
process for improvement and implementation of any actions necessary to resolve
nonconforming assets.
15.2 Requirements
A. The Seller is required to maintain documented information that defines the
roles and responsibilities, including controls for resolving nonconforming
assets. This process may be supported and documented as part of Seller’s
Quality Management System (QMS). Typical assets nonconforming elements
include:
1. Personnel qualification.
2. Nonconformance forms used for assets.
3. Discrepancy communication and formal initiation.
4. Asset release status identification (visual indicator).
5. Discrepancy disposition response, approval, work-around by Seller and/or
Boeing.
6. Closure of the non-conformance.
B. Any asset identified as deviating from design/definition or causing a product
nonconforming condition must be documented in accordance with this
document. Nonconforming conditions will be processed per Purchase
Contract (Ref. section 1.2 General Requirement) and/or Seller’s
nonconformance process up to and including potential product impact
investigation per section 16.2 (Potential Product Impact).
C. All nonconformance documented information must be controlled per Seller’s
Quality Management System (QMS) and maintained per section 19 (Records).
D. Boeing does not delegate asset nonconformance disposition authority to
Seller’s.
1. Where Boeing Defense, Space & Security (BDS) procurement supports
Boeing accountable and Government own Boeing accountable assets all
identified nonconforming conditions will be documented per Purchase
Contract (Ref. section 1.2 General Requirements), and submitted to
Boeing (ref. section 1.4 Seller Communication) to obtain approved
disposition.
2. Where Boeing Commercial Airplanes (BCA) procurement supports
Boeing accountable assets Seller may document per internal Quality
Management System (QMS) to resolve asset nonconformance condition(s)
using current Boeing approved asset design/definition.
a. When asset nonconforming condition(s) cannot be resolved with
current Boeing approved design/definition, nonconformance
documents must be submitted to Boeing (ref. section 1.4 Seller
Communication) to obtain Boeing approved disposition.
E. All Category I (CAT I) master tools identified with nonconforming
condition(s) must immediately be documented per Purchase Contract (Ref.
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section 1.2 General Requirements), and formally submitted to Boeing (ref.
section 1.4 Seller Communication) to obtain Boeing approved disposition.
1. A discrepant Category I (CAT I) master tool must not be used until
Boeing has provided technical and/or contractual instructions received in
writing.
F. Unless otherwise specified in Purchase Contract (Ref. section 1.2 General
Requirements), a nonconformance document that is submitted for disposition
will include, at a minimum, the following information:
1. Complete Asset identification as defined on asset (e.g., basic number,
code, ownership, revision level, etc.).
2. Asset unit/duplicate number, when applicable.
3. Asset Lifetime Serial Number or Purchase Contract serial number, when
applicable.
4. Asset Nomenclature (e.g., defined name, defined function, etc.).
5. Asset source authority (i.e., design/definition, drawings, digital data,
master tool, mylar type layouts) including source authority revision, which
was used to determine nonconforming condition.
6. A complete and concise description of the discrepancies, including source
authority “Should Be” and “Is” condition, include drawing location and
asset details affected.
7. Any accepted measurement results to define/identify discrepancy.
8. Any graphics, sketches, drawings, photographs, or Seller nonconformance
record necessary to clarify the discrepancy.
G. When providing nonconformance documents to Boeing this information must
be in English and imperial measurement system when submitting.
H. Nonconforming assets must not be released to or used by Seller’s
manufacturing organization until the asset is corrected per current Boeing
design/definition and/or verified per Boeing approved disposition.
I. Where an alternate manufacturing or asset usage method (e.g., work around
plan, limited use process, etc.) has been identified, planned, documented and
approved in accordance with Seller’s capability and nonconformance process.
All alternate manufacturing method plans must be submitted to Boeing (ref.
section 1.4 Seller Communication) for technical approval prior to
implementation and use.
J. An acceptable alternate method plan must, at a minimum, contain the
following:
1. Specific and explicit workaround instructions that will ensure resulting
production hardware will be in conformance with engineering
requirements including Category I (CAT I) master tooling, as applicable.
a. Any Category I (CAT I) master tools (gages) determined to be
deficient must be brought to the attention of Boeing immediately per
section 15.2 D.
2. Optical location or hand layout methods may be utilized in lieu of asset
where critical and/or close tolerance dimensional engineering
requirements exist, such as Interchangeable & Replaceable (I&R) items.
3. The workaround plan duration stated by one of the following:
a. Calendar Date, Manufacturing days, Unit numbers, Airplane
line/variable number, Lot Number.
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b. An active asset work authorization order completion date that will
correct the discrepant condition.
c. A nonconformance report completion date that will correct the
discrepant condition.
4. The Seller’s authorization (i.e., Quality Management, Manufacturing
Engineering Management, and/or Tooling Management), concurrence and
approval of all the above elements is documented.
5. Seller must coordinate with Boeing (ref. section 1.4 Seller
Communication) to obtain contractual instruction for technical approval of
any work around plan that is generated where a contractual asset is not
used or rework may impact product or product delivery schedule.
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16.0 Potential Product Impact
16.1 Scope
This section defines the Seller responsibilities to investigate assets to identify and
prevent occurrence or reoccurrence of product nonconforming conditions as a
result of asset usage. This includes Customer complaints, Seller or Seller
subcontractors identified product or asset nonconforming conditions.
16.2 Requirements
A. Asset discrepancies potentially impacting products must invoke a Potential
Product Impact (PPI) investigation as defined by Seller’s Quality
Management System (QMS), i.e., Improvement, Nonconformity, and/or
Corrective Action process.
B. Seller must support Boeing with asset event-based Potential Product Impact
(PPI) investigations. Seller must document results of asset related Potential
Product Impact (PPI) investigation per Quality Management System (QMS)
requirements for corrective and preventative action.
C. When identified, Seller must document any nonconforming asset within
Seller’s nonconformance process and identify, document, and segregate
nonconforming assets from manufacturing use until asset is corrected or an
alternative method is approved per section 15 H&I (Nonconformance).
D. Asset nonconformance types requiring further investigation for Potential
Product Impact (PPI) include but are not limited to the following:
1. A dimension or feature that is out of tolerance and results in a product
exceeding engineering definition tolerances.
2. Damage to the asset identified after usage.
3. Incomplete asset used to produce product (e.g., missing parts, sub-
assemblies, details, etc.).
4. Asset used with incomplete or missing identification (e.g., missing
configuration, acceptance, etc.).
5. Asset used prior to final acceptance (i.e., no evidence of asset acceptance,
completed first piece inspection prior to asset acceptance).
6. Missing or altered asset tamper proof measures.
Investigation may show that these conditions did not have an adverse effect on
the product, however focus on internal process compliance must be addressed
to eliminate these asset escapes as required in section 10 (Each Use Condition
Checks) and section 13 (Preventive Maintenance).
E. Seller must notify Boeing (ref. section 1.4 Seller Communication) upon
initiation of Potential Product Impact (PPI) investigations where a potential
product escape has occurred and make investigation results available to
Boeing upon request.
F. Seller must identify the produced products (designated by serial number, lot
number, date codes, any other available means) potentially nonconforming as
a result of a nonconforming asset. Seller must ensure any suspect product or
work in progress or produced product (in-stock) are verified and/or re-verified
per Seller’s Quality Management System (QMS) acceptance processes up to
and including initiation of nonconforming product documentation.
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G. Seller must formally and immediately report all assets nonconformance
conditions and issues potentially impacting product where a Notice of Escape
(NOE) is formally documented per the requirements of this document and
Seller’s Quality Management System (QMS). Submit formal notifications to
Boeing (ref. section 1.4 Seller Communication) per contractual instructions.
This activity/process must include products at Seller’s and its subcontractors’
facilities, and products previously delivered to Boeing.
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17.0 Receiving and Shipping
17.1 Scope
This section applies to all receipts and shipments of assets by Seller and its
subcontractors. Seller and its subcontractors must satisfy the following
responsibilities to avoid asset loss and damage during receipt and shipment. This
section applies to all Boeing accountable and Government owned Boeing
accountable assets.
17.2 Requirements
A. Sellers must maintain documented information to receive and ship assets.
Documented information must include formal receipt, accountability, and
traceability of all assets, including storage of asset per section 14 (Protection
and Storage). Where Seller maintains a Government approved property
accountability process, Seller receipt of Boeing accountable Government
property must be controlled per Government approved accountability process
including any additional requirements of this document where applicable.
Seller must formally notify Boeing (ref. section 1.4 Seller Communication)
for any asset receiving or shipping related questions or instructions.
B. Seller must follow requirements of E000 (Supplier Requirements for
Buyer/Government/Customer Property Management) and/or D33113-1
(Accountability of In-Plant/Out-Plant Special (Contract) Tools) for any
Boeing accountable asset and Government owned asset accountable to Boeing
received by Seller.
C. Assets received or being prepared for shipping or in transit to storage or usage
areas must be controlled in such a manner as to prevent corrosion, oxidation,
contamination, environmental exposure, damage or loss.
D. Any asset received or shipped in support of a Boeing Purchase Contract must
be controlled per this document. Typical assets received or shipped include
but are not limited to:
1. Special Tooling (ST) including mylar type layouts
2. Special Test Equipment (STE)
3. Production Equipment
4. Mechanical Handling Equipment (Overhead and transport)
5. Data Elements (usage instructions, design/definition – including digital
data, mylar type layouts, asset reports, etc.)
6. Physical and digital authority assets (Category I CAT I master tools,
Master Tooling Parts, Sample Parts, Sample Assemblies, etc.)
E. Any discrepancies found during receiving or shipping actions, including asset
screening must be properly documented and addressed in accordance with
Seller’s Quality Management System (QMS) and section 15
(Nonconformance).
1. Any Category I (CAT I) Master Tool discrepancies require the Seller to
suspend use of the master tool, isolate and control the master per the
requirements of this document, and immediately contact Boeing (ref.
section 1.4 Seller Communication) for technical and/or contractual
instructions.
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F. All assets will be incorporated into Seller’s asset control processes for
accountability, use and storage (Ref. section 14 Protection and Storage)
including any data element used in support of a Boeing Purchase Contract.
Retaining photographs of asset condition at time of receipt is encouraged.
17.3 Receiving
A. Where an asset is furnished in an “as-is” condition and accepted by the Seller,
any repairs, replacement, and/or refurbishment will be at Seller’s expense.
B. Upon receipt all assets must be screened. All screening activity must be
accomplished using asset design/definition, Original Equipment Manual
(OEM) and/or associated documents. At time of receipt if no
design/definition, Original Equipment Manual (OEM) and/or associated
documents are provided immediately notify Boeing (ref. section 1.4 Seller
Communication) to obtain documents or contractual instructions prior to
performing screen activity. Seller must maintain asset screening records (ref.
Exhibit A) and control screening records per section 19 (Records).
C. Asset screening includes at a minimum:
1. Verify the asset identification is accurate and legible as defined per
shipping and contractual documentation including evidence of asset
acceptance status (Ref. section 8.2K Acceptance).
2. Verify the tool is in safe working condition and will not present any safety
issues.
3. Visually inspect tools for Foreign Object Debris (FOD), damage, and any
visible excessive wear.
4. Verify accountability of all parts and details of the tool (requires
engineering design/definition documentation).
5. Verify received asset configuration (Ref. section 3.3 Configuration
Management) aligns to the asset design/definition, bears evidence of
acceptance, (impression stamping, chemical or mechanical etch, or unique
identifier).
6. Review / Verify preventative maintenance, (calibrations, proof load tests
labels and certifications, periodic inspection labels) are current and up to
date where applicable.
7. Verify and initiate any preservation activities per section 14 (Protection
and Storage).
D. When receiving Category I (CAT I) Master tool with dedicated Master
container (Sealed), Seller must contact Boeing (ref. section 1.4 Seller
Communication) 5 days prior to opening any master tool container. Boeing
reserves the right to witness the opening and closing of Master tool containers.
Seller must request formal technical authorization whenever opening a sealed
master container from Boeing (ref. section 1.4 Seller Communication).
E. When opening Category I (CAT I) Master tool containers the following
screening must be performed when authorized:
1. Inspect master tool container for identification, damage and
deterioration/contamination.
2. Verify the integrity of tamper proof seals on containers are intact.
3. Remove all container seals.
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4. Perform asset screening per 17.3 A, B & C before removing the master or
components from the master tool container.
5. Complete “Tooling Inspection Gage Storage Record (TIGSR)” (X22220).
Ensure that current forms are attached to any obsolete forms with similar
data to retain historical records.
6. Complete “Tool Configuration Management Record (TCMR)” (X31068).
Ensure that current forms are attached to any obsolete forms with similar
data to retain historical records.
17.4 Shipping
A. Unless otherwise specified per Purchase Contract all shipping of any asset
must meet or exceed the minimum requirements as defined in asset
Design/Definition, Terms & Conditions (T&C), General Provisions (GP),
and/or Special Provisions (SP), including D37522-6 (Supplier Packaging).
1. Where Purchase Contract specifies Advanced Shipping Notice (“ASN”)
and/or submittal of Transportation Plan supplier must follow General
Provisions (GP) and D37522-6 instructions prior to asset shipping.
B. Seller must maintain documented information that defines asset shipping
processes that includes but is not limited to the following:
1. Packing/Packaging – Ensure the packing or packaging provides asset
protection to prevent damage and/or deterioration during shipment.
(Reference D3951 (Standard Practice for Commercial Packaging) for
industry recognized packaging processes).
2. Cleanliness - Asset must be free of foreign object debris (FOD) and other
contaminants which would contribute to deterioration or which would
require cleaning by the customer prior to use. Preservatives applied to an
asset for protection are not considered contaminants.
3. Preservation - Assets susceptible to corrosion, oxidization or deterioration
(i.e., bare metal, unfinished surfaces, etc.) must be provided protection
such as preservative coatings, barrier protection, volatile corrosion
inhibitors, and/or substance used as a drying agent such as desiccant
packs.
4. Cushioning / Shoring – During packaging provide any necessary blocking,
bracing, cushioning, to prevent asset damage and ensure a safe delivery.
C. In preparation for shipment, all assets must be screened as defined in section
17.3 B & C. All screening activity must be accomplished using asset
design/definition, Original Equipment Manual (OEM) and/or associated
documents. If no design/definition, Original Equipment Manual (OEM) and/or
associated documents are available immediately notify Boeing (ref. section
1.4 Seller Communication) to obtain documents or contractual instructions
prior to packaging and shipping.
1. Shipment screening must include verification of deliverable records
package is complete per section 19 (Records).
2. No asset with an open nonconformance record will be shipped without
formal shipping authorization from Boeing (ref. section 1.4 Seller
Communication).
D. Shipment of Category I (CAT I) Master tool from the Seller’s facility,
including to Seller’s alternate locations or a subcontractor requires formal
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authorization from Boeing (ref. section 1.4 Seller Communication) and must
not be shipped until written authorization is received.
E. Boeing reserves the right to verify Category I (CAT I) Master tool shipping
preparation prior to closing/sealing container. When Boeing verification of
master tool shipping preparation is identified or required, Seller must contact
Boeing (ref. section 1.4 Seller Communication) to coordinate attendance.
F. Seller must ensure Category I (CAT I) Master tool shipping containers are
free from damage and in a serviceable condition prior to master installation.
Master tool containers must prevent environmental or physical damage and
allow for safe transportation of master tools.
1. Seller must formally notify Boeing (ref. section 1.4 Seller
Communication) for instructions when Master Tool containers are
identified with visible damage or missing components.
2. Under no circumstances will a Master tool being prepared for shipping be
stored outside regardless if stored in a master tool container or not.
G. Category I (CAT I) Master tool screening and preparation must also include
the following:
1. Ensure all loose master detail parts (chained parts, bushings, pins,
detached assembly components, etc.) are accounted for and in shipping
container.
2. All bare metal and critical surfaces must be protected from contamination
by applying appropriate preservative to prevent corrosion or oxidization.
3. Ensure all master tool container shoring, supports, and cushioning are in
place and functional.
4. Ensure no Foreign Object Debris (FOD) is in master container.
H. Where authorization is granted to Seller to conduct Category I (CAT I) Master
tool screening, preparation for shipping (Ref. section 17.4 Shipping), and
sealing of Master Tool container, Seller must:
1. Verify all contents in the master tool container.
2. Ensure all critical indexing surfaces are protected.
3. Ensure all detail parts are supported and secured within the master tool
container.
4. Ensure all Foreign Object Debris (FOD) is removed prior to closure.
5. Complete all sections of the Open/Close Log (Ref. X22220 form).
Typically completed while performing a preparation / screening event.
6. Ensure open/close log and master tool design/definition, including when
appropriate Configuration Record form is inside container prior to sealing.
I. At each Category I (CAT I) Master tool closure event, after the lid/top has
been secured, the lid/top will be wired and sealed at two opposite sides or
ends, including any latches if applicable. (Ref. D33181-62 Sealing of Master
Tools and Containers).
J. Seller must formally notify Boeing (ref. section 1.4 Seller Communication)
for any shipping related issues or questions to obtain contractual instructions
to proceed.
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18.0 Post-production and Spares
18.1 Scope
This section addresses post-production and spares use of assets including all
variations of the terms post-production and spares (e.g., fleet modification
programs, upgrade programs, service bulletins, warranty programs, maintenance
programs, etc.). The scope covers all categories of Boeing owned and Boeing
accountable Government owned assets used to produce Boeing or Government
products under a Boeing post-production or spares Purchase Contract.
18.2 Requirements
A. Seller must ensure assets that are defined, fabricated, received, or otherwise
provided for the purpose of implementing a post-production or spares program
is in compliance with all requirements of this document.
B. Seller must confirm the asset configuration for the purpose of manufacturing
and/or acceptance requirements as defined in Purchase Contract.
C. Any assets used to support post-production or spares program deemed
Configuration Critical, Media of Inspection (MOI) or Inspection Media of
product for the purpose of acceptance/inspection requirements must meet the
intended configuration as defined in Purchase Contract.
D. Seller and their subcontractors must have a documented asset post-production
process and must keep assets, including stored assets, in a serviceable
condition. Seller and their subcontractors must have the following but not
limited to:
1. The asset design/definition for the current Boeing accountable asset
configuration being used.
2. The applicable latest revision of the Boeing-defined specifications
including usage instructions, Original Equipment Manual (OEM) and any
required documentation for asset usage.
E. If asset design/definition is not available at Seller or their subcontractors the
Seller must coordinate with Boeing (ref. section 1.4 Seller Communication)
to obtain instructions for resolution.
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19.0 Records Requirements
19.1 Scope
This section defines the requirements for creation, retention and delivery of
documented information (records) generated during development, creation,
verification, use, maintenance and storage of assets.
19.2 Requirements
A. As defined in this section, records creation, retention, and delivery does not
supersede, nor is it intended to contradict with Boeing or Government
Property Management requirements (Ref. E000 Supplier Requirements for
Buyer/Government/Customer Property Management and/or D33113-1
Accountability of In-Plant/Out-Plant Special (Contract) Tools). Seller must
formally address any conflict of requirements with Boeing (ref. section 1.4
Seller Communication).
B. Seller must retain documented information (Records) to ensure processes
were carried out as planned. Records must be controlled and include:
1. Completed results of planned asset processes, including changes. (e.g.,
work authorization, shop travelers, etc.)
2. Approved design/definition input and output and revisions, including
usage instructions and operation manuals.
3. Approved change authorization.
4. Verification results. (e.g., inspection, acceptance, test, etc.)
5. Special process conformity. (e.g., welding, heat treating, dye penetrant,
etc.)
6. Documentation of nonconforming conditions and dispositions.
7. Approved /accepted documented information.
8. Defined retention periods and dispositions, including digital archive,
typically asset life cycle or as defined by Purchase Contract.
C. All records for Boeing owned or Government owned Boeing responsible
assets must be made available upon request, including electronic format.
Typical asset records include, but are not limited to, the following:
Certificate of Conformance
Proof Load Test Records (Certification)
Special Process Records (Certification)
Work Authorization Records
Inspection Records including digital data
Asset Completion Records (Certified Tool List – D141010600, Tool
Completion Reports (e.g., MD-2045, DAC26-611), Including invoices,
property list, and/or property records submitted in Boeing’s electronic data
system - Ref. section 1.2 General Requirements)
Screening Records
Periodic Inspection Plans (PIP)
Periodic Inspection Records / Results
Preventive Maintenance Plans (PMP)
Periodic Maintenance Records / Results
Nonconformance Records
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D. Unless otherwise specified in Purchase Contract (Ref. section 1.2 General
Requirements), the following records must be provided as part of asset
shipment when:
1. Seller has executed any Purchase Contract that procures
Design/Definition, initial fabrication, rework or modification and delivery
of an asset. Records must include the following:
a. Certificate of Conformance
b. Design/Definition
c. Data Elements (usage instruction, manuals, plans, data, etc.) when
applicable.
d. Proof Load Test Certification (when applicable)
e. Special Process Certification (when applicable)
f. Inspection/acceptance Records, including build logs & digital
measurement records when required.
g. Screening Record.
h. Nonconformance Records (disposition complete /closed)
i. Photograph(s) of asset condition as part of delivery package is
encouraged.
2. Seller has executed a Purchase Contract, including line items that
authorizes creation, retention, and usage of an asset the following records,
at a minimum, must be provided to Boeing (ref. section 1.4 Seller
Communication) upon asset completion:
a. Certificate of Conformance
b. Asset Completion Records (Certified Tool List – D141010600, Tool
Completion Reports (e.g., MD-2045, DAC26-611), Including invoices,
property list, and/or property records submitted in Boeing’s electronic
data system)
3. Seller processing an asset as a user closeout and/or return to Boeing,
including a Boeing or Government storage facility, relocate asset to
alternate location or relocate asset due to Purchase Contract completion or
termination, records must include the following:
a. Design/Definition
b. Data Element Data Elements (usage instruction, manuals, plans, data,
etc.)
c. Proof Load Test Certification (when applicable)
d. Inspection/acceptance Records, including build logs & digital
measurement records when required.
e. Screening Records.
f. Periodic Inspection Records (when applicable)
g. Periodic Maintenance Records (when applicable)
h. Nonconformance Records (disposition complete /closed)
i. Photograph(s) of asset condition as part of delivery package is
encouraged.
D. Records may be submitted via Boeing approved electronic data system (ref.
section 1.4 Seller Communication) and/or hard copies as defined in Purchase
Contract (Ref. section 1.2 General Requirements), Seller must contact Boeing
(ref. section 1.4 Seller Communication) for record delivery process in support
of a Purchase Contract.
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19.3 Records
A. Unless otherwise defined per Purchase Contract (Ref. section 1.2 General
Requirements), records must meet the following criteria:
1. Certificate of Conformance (CoC) - Must contain a statement indicating
the identified asset was manufactured and is conforming to the approved
asset design/definition and/or fabrication specification (Ref. Exhibit B).
a. Each asset will be documented on an individual single Certificate of
Conformance (CoC). Multiple assets may be listed on a single
Certification of Conformance (CoC) where duplicate assets are
fabricated under a single Purchase Contract.
b. Unless otherwise specified by Purchase Contract, a Certificate of
Conformance (CoC) will be used to communicate and document asset
completion(s) to the Buyer’s Authorized Procurement Agent (APA).
c. The Certification of Conformance (CoC) will contain but not be
limited to the following information documented:
1) Seller Name, address, contact information, BEST Code,
manufacturing address (i.e., the address from where the asset was
shipped or the asset resides)
2) Date of Certificate of Conformance (CoC) origination (i.e., date
the asset was accepted and ready for use)
3) Purchase order number on Purchase Contract
4) Attn: Buyer’s Authorized Procurement Agent (APA) - name and
contact information.
5) Reference information (Ref section 1.2 General Requirements).
6) Asset design/definition and revision (i.e., digital data-full file
name, 2D drawing number, mylar type layout, etc.)
7) Asset description (i.e., asset series if required, asset name, asset
number, asset code, asset category, asset type, and brief description
of asset function)
8) Asset Life-time or Purchase Contract serial number (when
applicable)
9) Seller’s asset work authorization document number (i.e., shop
traveling, tool order, work order, etc.,)
10) Nonconformance documentation numbers if applicable. (i.e.,
approved dispositions, use as is, rework, replacement of assets)
11) Signature or acceptance stamp of Seller’s QA manager (or their
designee) or responsible company officer.
2. Proof Load Test certificate (Ref. section 8.4 Proof Load Test) will include:
a. Seller Information (Name, address, contact)
b. Purchase Contract number
c. Asset number, name, including serial number as applicable
d. All required proof load design/definition (e.g., sheets, diagrams, cases,
graphic, etc.) and specification requirements (e.g., duration,
compression, tension, torque, etc.)
e. List of all proof load test equipment/device (e.g., load cells, scales,
weights, etc.) including certification dates and property/identification
f. Personnel accountability performing proof load test
g. Certificate date, signature and stamp
h. Customer acceptance (Boeing witness when applicable)
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i. Pre/Post Visual and non-destructive examination reports (when
applicable)
3. Inspection/acceptance records (Ref. section 8 Acceptance) will contain at
a minimum, but not limited to:
a. Actual measurement results “as built” for:
1) All Geometric Dimensioning and Tolerancing (GD&T) explicit
defined features regardless of tolerance.
2) All critical tolerances are documented and accepted (+/- 0.015
and less).
3) Evidence of inspection of all features, material, processes,
general notes, etc. is required. Statistical sampling and sampling
plans are not allowed for asset acceptance.
4) All manual or Coordinate Measurement System (CMS)
documented dimensions will be traceable to the person(s)
performing the inspection and date it was accepted/completed.
5) Test/Qualification/Functional results when applicable. (Hydraulics,
air, vacuum, drilling, fastening, bonding, etc.)
b. Coordinate Measuring System (CMS) reporting – Refer to D6-51991
Control of Measurement Equipment.
4. Special Process Records (Ref. Section 7 Special Processes) will include
evidence that all material and special process specification are
inspected/verified, including but not limited to the following:
a. Welding certification (AWS specification, etc.)
b. Nondestructive Test/Inspection certification (Dye penetrant, Mag
Particle, Material hardness/tensile, etc.)
c. Heat treatment certification (meets Nadcap specifications)
d. Stress relief certification (fabrication specification)
e. Protective finish (paint, coatings, etc. - fabrication specification)
f. Material Finish certification (chrome, cadmium plating, nitride
coating, etc. – fabrication specification)
5. Work Authorization (shop travelers, work orders, tool orders, etc.)
Records (Ref. section 4 Asset Design/Definition & section 6 Fabrication,
Rework, and Modification) will include, at a minimum:
a. Unique Work Authorization number
b. Asset identification (unique asset number including series, code, base
number, including unit number)
c. Asset Serialization (i.e., life time serial number, as applicable per
Purchase Contract)
d. Coordination data (asset design/definition, authority datasets, gages,
mylar type layouts, etc. including all applicable sheets and revisions)
e. Specifications (fabrication standards and special process
specifications, including revisions)
f. Purchase Contract Number (traceable to asset procurement or purchase
contract line item procurement.)
g. Materials (listing of commercial of the shelf and defined materials)
h. Sequential instructions necessary to fabricate, assemble, verify/test
(including in-process inspection.)
6. Seller must maintain asset inspection records or build logs per Purchase
Contract (Ref. section 1.2 General Requirements), in support of assets
Initial Fabrication, Rework, or Modification (Ref. section 6) and Asset
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Acceptance (Ref. section 8). Inspection records, including build logs may
be documented on Seller equivalent forms. Asset inspection records and/or
build logs must be provided as part of asset delivery package.
a. Inspection records, including build log forms (Ref. MAC1147 series
forms), at a minimum this documented information (See Section 6.2 D
and 8.2 G) must contain the following:
1) Asset number and name (unique asset number including series,
code, base number, including unit number, detail number,
assembly number etc.) associated with Design/Definition bill of
material (BOM).
2) Asset Serialization (i.e., life time serial number, bar codes, as
applicable per Purchase Contract).
3) Characteristic Number (traceable identifier assigned to
Design/Definition characteristic).
4) Reference Feature Location (location of Design/Definition location
– drawing zone, sheet number, Digital Data location, specification
callout, etc.).
5) Characteristic Designator (designed characteristic type).
6) Requirement (Specified requirement for the design characteristic
(e.g., drawing or DPD dimensional characteristic with associated
nominal dimension and tolerances, drawing notes, specification
requirements).
7) Results (listing of actual measurements obtained for the design
characteristics for each characteristic designator). Including
reference to Coordinate Measurement Machine (CMS) results for
positional values (CMS results/report must meet D6-51991 Quality
Assurance Standard for Digital Product Definition at Boeing
Sellers).
8) Nonconformance number (reference number for characteristics
found outside design/definition requirements).
9) Signature or acceptance stamp of authorized operator or inspector
(traceable to each page of inspection record/build log).
b. Where program specific documented information (inspection record,
build log form, etc.) is requested, Seller must formally contact Boeing
(ref. section 1.4 Seller Communication) to obtain instructions and any
requested forms.
7. Seller must maintain Periodic Inspection Plans (PIP) and Periodic
Inspection results as part of records retention (Ref. section 9 Periodic
Inspection). Seller must retain revision history of Periodic Inspection
Plans (PIP) including current and preceding Periodic Inspection results.
These records must be made available to Boeing upon request.
a. Where Boeing Defense, Space & Security (BDS) procurement
supports Boeing owned and Government own Boeing accountable
assets all Periodic Inspection Results per section 9 (Periodic
Inspection) must be sent to Boeing (ref. section 1.4 Seller
Communication) within 30 days of completion (Ref. section 9.2 G
through L).
b. Where assets are recalled by Boeing to perform asset Periodic
Inspection actions in support of a purchase contract or Seller is not
capable of asset Periodic Inspection (Ref. section 1.3 a. –
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Subcontractor General Requirements) and returned to Boeing, Seller
accountability and maintenance of Periodic Inspection results is not
mandatory. Seller is still required to maintain asset Periodic Inspection
status per section 9 (Periodic Inspection) including Category II listing,
recall dates, Subcontractor results, etc.
8. Seller must maintain Preventive Maintenance Plans (PMP) and Preventive
Maintenance (Ref. section 13 Preventive Maintenance) results as part of
records retention. Seller must retain revision history of Preventive
Maintenance Plans (PMP) including current Preventive Maintenance
result. These records must be made available to Boeing upon request.
9. Seller must maintain asset nonconformance (Ref. section 15
Nonconformance) history as part of records retention. Where
nonconformance documentation is generated Seller must:
a. Submit to Boeing for approved disposition.
b. Submit nonconformance documentation as part of delivery/shipping
package (when applicable).
c. Make any nonconformance documentation available upon request.
d. Submit nonconformance documentation to Boeing (ref. section 1.4
Seller Communication) and/or Boeing’s electronic data system when
required.
10. Seller must maintain Screening records (ref. section 17.3 & 17.4) history
as part of records retention. Screen records must document (ref. Exhibit A)
at a miniumn as follows:
a. Identifible information (supplier name, address, date, contract #,
shipping number, asset number and revision, ect.).
b. Screen event type (Receiving or Shipping).
c. Customer notifications and authorizations (e.g. shipping with open
nonconformance, Category I (CAT I) master shipping, customer
witness, etc.).
d. Screening actions (Receiving ref. section 17.3 C & E – Shipping ref.
section 17.4 C, G, H &I). and acceptance and rejection status.
e. Tracability to any Nonconformancing condition identified during
Screening event.
f. Tracability of inspection / acceptance authority of the individual
performing screening event.
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20.0 Definitions of General Terms
Adjustable Datum Feature: features that are adjustable, identified, and control the
designed datum structure of the asset (e.g., surfaces, planes, lines, points, candlesticks,
tool balls, and tool buttons).
Asset: Property of all kinds, real and personal, tangible and intangible. For purposes of
this standard an asset typically includes: Special Tooling (ST), Special Test Equipment
(STE), Handling Equipment or Production Equipment and associated data elements.
Asset Screening - The process that assures all production assets being received and
shipped to/from a Seller facility is visually sound, in working order and built to the
appropriate engineering revision.
Authorized Procurement Agent (APA): a person with Signature Authority delegated in
writing who is authorized to make Purchase Contracts, Commitments, or agreements with
Providers of Goods or Services on behalf of The Boeing Company.
Boeing Accountable Asset: Asset that is maintained by Boeing Property Management
and consists of those asset types that are identified, including serialized assets, and
tracked when stewardship or location changes occur. Accountable assets may consist of
Government-Furnished Property (GFP), Contractor-Acquired Property (CAP) Customer-
Furnished Property (CFP), Government-owned Boeing-accountable assets, and/or
Boeing-owned assets.
Boeing-defined: Any Boeing Asset definition, fabrication order, inspection plan,
periodic inspection plan, work authorization, contract requirements formally released to
the Seller.
Boeing-defined Asset: Boeing controlled asset definition, fabrication standards /
requirements for Boeing accountable asset.
Capital Equipment: Instruments, power sources, etc. of a general-purpose nature, which
are not charged to a specified contract or are Boeing accountable.
Certificate of Conformance (CoC): A type of quality certificate that is certified by a
competent authority to verify that the supplied goods or services meet required
specifications.
Configuration Alignment: The process of ensuring the asset configuration is consistent
with product engineering revision levels as defined by contract requirements. All the
elements of definition, identification, and disposition of materials, parts, assemblies, and
installations, including the complete technical description required to fabricate, test,
accept, operate, maintain, and logistically support systems and equipment.
Configuration Change and Variance Management: A documented systematic process
for identifying, approving and controlling changes and variances to engineering
design/definition requirements and product engineering.
Configuration Control/Management: The systematic control of an established and
approved baseline. Configuration control encompasses establishment of the initial
baseline for a work product and all subsequent authorized and approved changes to that
baseline. Including the control that ensures the asset configuration is aligned and
complete per asset design/definition throughout the asset life cycle until contract
closeout.
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Configuration Critical: A designation used for any asset because of its use, cost,
complexity, or key indexing features being defined or used during the manufacturing
process. Assets deemed Configuration Critical require a greater level of oversight.
Configuration Identification: Configuration identification is the basis by which product
configuration is defined and verified; products are labeled and documented; changes are
managed and accountability is maintained. Specifications, drawings, and other types of
configuration documentation or data define the configuration identification of a product.
The configuration identification of a product may also consist of additional product
information, such as technical manuals and users manuals, that is derived from the
configuration documentation or data. Proper configuration identification is essential to
provide technical and contractual control, verification, and approval for product
configurations and their interfaces.
Control Media: Assets made from masters, fixtures, gages, and templates and other
devices or appliances necessary for maintaining interchangeability or replaceability.
Items will be built with control media established and/or approved by the prime
contractor.
Coordinate Measurement Systems (CMS): A manually or numerically driven system
for dimensional measurement of parts/tools that may be comprised of hardware and
software capable of producing measurement results output in various formats (e.g.,
Coordinate Measurement Machine (CMM), Laser Tracker, Photogrammetry).
Design / Definition: Asset engineering that has gone through the verification process
and is ready for release and use. Asset engineering is defined by either a model or dataset
package and/or 2D drawing set that identifies and specifies components and their
integration into the complete asset (i.e., Special Tool (ST), Special Test Equipment (STE)
or Equipment) satisfying explicit and implicit fit, form, function, performance, capacity,
and financial requirements including any constraints, resulting in configuration,
specifications and bill of materials (BOM) required to produce the asset.
Digital Product Definition (DPD): The electronic data elements that specify the 3D
Computer Aided Design (CAD) geometry and all design requirements for a product
(including notation and parts lists), and the use of this data throughout an integrated
CAD/Computer Aided Manufacturing (CAM) and Coordinate Measurement Systems
(CMS).
Documented Information: May consist of documentation, quality manual, documented
procedures, and records. The structure and content of documented information related to
a quality management system relates to both the processes operated by the organization
and information maintained for other purposes.
End-Item: Category II Special Tools (ST) used to produce, control and/or accept
production end items (i.e., detail parts, assemblies) where Special Tools (ST) are the only
method of product acceptance. This includes Major End-Item Assembly tools used to
produce, control, and/or accept Interchangeable and Replaceable (I&R) Items,
Replaceable Items, Replaceable-Interchangeable at Attach Points Only Items, or
Interchangeable and Replaceable (I&R) Match. Typically, end-item tools special
requirements for Seller fabrication and use are identified per Design/Definition or
Purchase Contract requirements.
Equipment: A tangible asset that is functionally complete for its intended purpose,
durable, nonexpendable, and needed for the performance of a contract. Equipment is not
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intended for sale, and does not ordinarily lose its identity or become a component part of
another article when put into use. NOTE: Equipment does not include material, real
property, special test equipment (STE) or special tooling (ST).
Fit - As used in the phrase “Fit/Form/Function”: The ability of critical features of an
item to physically interconnect with or become an integral part of another item utilizing
the same attachment or mounting and mating surface as defined by the product definition
data (PDD) [drawing/model based definition (MBD)] or tool use instructions.
Example: A circumstance where the tool is unable to nest, index, mate, or be properly
offset per design.
Form - As used in the phrase “Fit/Form/Function”: The shape, size, dimensions, mass,
weight, other key characteristics or critical dimensions which uniquely characterize an
item. Other physical parameters will include the ability of the item to function
continuously in all respects within the original design envelope as defined by the PDD
(drawing/MBD). Example: The tool has had unauthorized parts, details, or material added
or deleted or deformation that precludes intended use.
Function - As used in the phrase “Fit/Form/Function”: The actions and properties that
an item is designed to perform and possess in relation to critical dimensions and critical
features as defined by the PDD (drawing/MBD). These actions and properties include,
but are not limited to, performance, operation, safety, strength, reliability, compatibility,
and maintainability. Example: The tool has been rendered non-functional for intended
use by significant damage, wear, or if systems related cannot perform without them.
General Purpose Equipment: Items that are not unique to any specific contract or
purchase order and is used to support production of parts or assemblies on multiple
products and/or programs (e.g., Portable/Perishable Tools, Hand Tools). As such these
tools are Seller-owned assets and are not accountable to Boeing under a Property
Management procurement clause.
Government - Furnished Property (GFP): Property in possession of, or directly
acquired by, the Government and subsequently furnished to the contractor for
performance of a contract. Government-furnished property includes, but is not limited to,
spares and property furnished for repair, maintenance, overhaul, or modification.
Government-furnished property also includes contractor-acquired property if the
contractor-acquired property is a deliverable under a cost contract when accepted by the
Government for continued use under the contract.
Government Property: All property owned or leased by the Government. Government
property includes both Government furnished and Contractor acquired property.
Government property includes material, equipment, special tooling (ST), special test
equipment (STE) and real property. Government property does not include intellectual
property and software.
Master Tool: A physical or digital source tool that includes interface control tools,
master control tools, master models, master gages, secondary gages, master templates,
master control drawings (MCD's), and master tooling parts. Master tools are commonly
referred to as Category 1 (CAT I) special tools, used as the configuration and fabrication
authority to establish basic nominal dimensional values for a tooling family. Master tools
are used in the construction, acceptance, and periodic inspection of special tools (ST) and
other assets.
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Media of Inspection (MOI): Asset designated for use in verifying product features or
characteristics of parts or assemblies are in compliance with engineering definition
requirements where designated Asset is the only means being used for acceptance.
Modification: An authorized physical change to an asset where asset design/definition
changes affecting fit, form or function are incorporated to ensure configuration
alignment.
Nadcap Accreditation: An aerospace industry managed accreditation program
administered by the Performance Review Institute (PRI).
Open/Close Log: A log or form (X22220 or equivalent) used to document when a
Category I (CAT I) master tool storage container is opened or closed while performing a
screening event.
Overhead Mechanical Handling Equipment: Any device used for lifting materials,
assemblies, fixtures, equipment, etc., that are made wholly or partially of materials such
as alloy steel chain, wire rope, metal mesh, synthetic webbing, welded adapters or any
combination thereof.
Periodic Inspection: Asset inspections performed and recorded on a periodic inspection
plan at a prescribed interval. Periodic inspections include physical dimensional
measurements and/or visual verifications.
Post-production and spares: Refers to the phase of a products life cycle after delivery to
a Boeing customer that includes post - delivery support and re-procurement of parts and
assemblies.
Potential Product Impact (PPI): A process of asset nonconformance analysis for the
potential impact to product features established or checked by the asset that may result in
nonconforming product.
Preventive Maintenance Plan (PMP): PMP is a process that defines, plans, and
completes specified maintenance tasks intended to provide timely inspection,
maintenance, and lubrication of contract tools to minimize malfunction or failure due to
wear or neglect.
Repair: Asset maintenance, which is necessary to keep assets in a
serviceable condition and defined configuration. Repair is limited to asset
maintenance items which do not alter asset configuration and/or affect fit,
form or function of an asset.
Rework: The altering of the asset, such as fit, form or function, including the
configuration of an asset to accommodate engineering changes, changes to asset usage,
and resolving asset nonconforming conditions.
Seller Accountable Assets: A production configured asset owned by the Seller to
produce product to support Boeing purchase contracts.
Seller-defined: Any Seller asset definition, fabrication plan, inspection plan, periodic
inspection plan, work authorization and physical asset controlled by Seller’s Quality
Management System. Seller controlled asset definition, fabrication standards/
requirements for Seller accountable assets.
Serviceable Condition: In good working condition, without damaged or missing
components, excessive wear, or any other conditions preventing an asset from performing
its intended function.
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Shop Aid / Manufacturing Aid Tools: A shop-made device to assist a particular
assembly/fabrication operator to do an operation more efficiently but is not required to do
the job every time. A shop aid is a non-designed, non-certified expendable item
fabricated and used by the factory during the manufacturing process that are consumed or
expended during a specific manufacturing process for which it was fabricated. Shop Aids
must not include any items that fall under the descriptions of equipment, special tooling
(ST), special test equipment (STE), or material. Shop aids are:
Control is dictated by functional/using department,
Generally a low cost item (e.g.,: less than $1,000.00),
Not required to do a job,
Not called out in work instructions,
Not used to control a design feature of a part or manufacturing process,
Never used for work acceptance of parts or processes,
Never used to control interchangeable features or replaceable parts,
Never used as a lifting device or test aid of any kind,
Never used as a safety item or for ergonomics, and
Never retained for follow-on use after completion of the specific manufacturing process
for which it was fabricated.
Special Test Equipment (STE): Single or multi-purpose integrated test units engineered,
designed, fabricated or modified to accomplish special purpose testing in performing a
contract. It consists of items or components that are interconnected and interdependent so
as to become a new functional entity for special testing purposes. It does not include
material, special tooling, facilities (except foundations and similar improvements
necessary for installing special test equipment), and plant equipment items used for
general plant testing purposes.
Special Tooling (ST): Jigs, dies, fixtures, molds, patterns, other equipment and
manufacturing aids, all components of these items, and replacement of these items, which
are of such a specialized nature that without substantial modification or alteration their
use is limited to the development or production of particular services or parts thereof or
to the performance of particular services. It does not include material, special test
equipment (STE), facilities except foundations and similar improvements necessary for
installing special tooling (ST), general or special machine tools, or similar capital items.
Specification: A document containing specific requirements for the design/definition,
fabrication, and inspection of an asset. Typically authored by Boeing and provided to
Seller for the purpose of asset identification of critical functionality, including but not
limited to, control, definition development, and fabrication.
Validation: Confirmation, through the provision of objective evidence, that the defined
requirements for a specific intended use or application have been fulfilled. Validation
may include full or partial measurement, testing, simulation or other techniques as
needed. Typically validation is a determination not a task.
Verification: Confirmation that defined requirements have been fulfilled. Verification
includes measurements, testing, simulation, modeling or other techniques, as needed, to
document acceptance evidence. Typically verification is a physical task and not a
determination. Asset verification consists of three types: minor verification; major
verification assembly, and major verification fabrication. (See section 8.3 Asset
Acceptance Methods for details of each type.)
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Work Authorization: Any approved document (e.g., Contract, Non-Conformance
document, Tool Order, Work Order, and Shop Traveler) that authorizes work to be
performed.
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21.0 References
AS9100, “Quality Management Systems – Requirements for Aviation, Space and
Defense Organizations”
AS9102, “Aerospace First Article Inspection Requirement”
D3951, “Standard Practice for Commercial Packaging for industry recognized
packaging processes”
D32028-1, “General Requirements for Tooling Welding”
D33011-0, “Boeing Tool Design Document”
D33011-23, “Stress Analysis for Engineering”
D33041-0 through -17, “Boeing Tool Identification Codes”
D33042-1, “Boeing Special Test Equipment, Agency Peculiar Property, and Plant
Equipment Identification”
D33113-1, “Accountability of In-Plant/Out-Plant Special (Contract) Tools”
D33181-40, “Tool Identification”
D33181-62, “Sealing of Master Tools and Containers”
D33200-1, “Boeing Supplier’s Tooling”
D33207-1, “Supplier Statement of Work for Special Tooling and Special Test
Equipment - BDS, BR&T, BT&E, BGS (Government Programs)”
D37522-6, “Seller Packaging”
D6-51991, “Quality Assurance Standard for Digital Product Definition at Boeing
Sellers”
D950-11288-1, “Product Definition Template (PDT) Requirements, Validation and
Verification Processes, and Handling Instructions for Plot Centers and Seller Use”
E000, “Supplier Requirements for Buyer/Government/Customer Property
Management”
MAC1147S, “Tool Build Log Summary”
MAC1147DA, “Tool Build Log Detail Accountability”
MAC1147CS, “Tool Build Log Construction Point Sketch”
MAC1147DB, “Tool Detail Information”
MAC1147E, “Tool Build Log Hole Pattern”
MAC1147D, “Tool Build Log Documentation”
MAC5420, “Quality Calibration Log”
AM0044, “Laminate Tool Build Log”
X22220, “Tooling Inspection Gage Storage Record (TIGSR)”
X30613, “Gageless Tooling Conversion Request”
X31068, “Tool Configuration Management Record (TCMR)”
X35200-2, “Gated Tool Design Record”
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Exhibit A
Example Asset Screening Record
Supplier Name &
Address:
Hawks Aviation LLC (HAL) 12345 Aero Ave. Everett, Wa. 98201
Tool Number
Rev.
Screening Event
Shipper #
P.O. / Order
#
FAJ112W1000-1
New
Receiving Shipping
ZYX321
9876543
Design / Definition
Used
NCR
Issued
NCR / CA #
Customer Notification /
Shipping Authorization
Required
Yes No
Yes No
Yes No
Accep
t
Reject
1
Verify the asset identification is accurate and legible as defined per
shipping and contractual documentation including evidence of asset
acceptance status.
2
Verify the tool is in safe working condition and in servicable condition.
3
Visually inspect tools for Foreign Object Debris (FOD), damage, and
any visible excessive wear.
4
Verify accountability of all parts and details of the tool (requires
engineering design/definition documentation).
5
Verify received asset configuration aligned to asset design/definition,
bears evidence of acceptance, (impression stamping, chemical or
mechanical etch, or unique identifier).
6
Review / Verify preventative maintenance, (calibrations, proof load tests
labels and certifications, periodic inspection labels) are current and up to
date where applicable.
7
Verify receiving no contamination (oxidization or corrosion). Shipping
verify / initiate application of preservation compound.
Category I (Master control tools, Master Gages, Etc.) Including 1-7
9
Inspect master tool container for identification, damage and
deterioration/contamination.
10
Verify the integrity of tamper proof seals on containers are intact when
Receiving.
11
Customer notification and witness Open / Close complete, when required.
12
Complete or update all sections of Open / Close Log - Tooling Inspection
Gage Storage Record (TIGSR), Tool Configuration Management Record
(TCMR), including of hard copy of Tool Design Drawing.
13
Open / close log and hard copy of Tool Design Drawing in Master
container, container sealed at two opposite sides or ends, including any
latches if applicable.
14
Customer shipping authorization received.
Comments:
Date
Acceptance
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Exhibit B
Example Certificate of Conformance
Hawks Aviation LLC (HAL)
12345 Aero Ave.
Everett, Wa. 98201
Date: 1/21/2017
From: John Doe
Title: Quality Manager
BEST code: BE2003286
Attn: G. Buss (BCA SM-PA)
Subject: Certificate of Conformance for FAJ112W1000-1 Unit 3 Boeing S/N 1234567 “777 L/H Rear Spar
Assembly Jig”
This Certificate of Conformance is used to document the conformance of FAJ112W1000-1 to the
contract purchase order requirements contained in PO# 9876543 and the approved tool design as
follows;
1) Tool drawing FAJ112W1000-1 sheet 1 rev “New”
2) Tool drawing FAJ112W1000-1 sheet 2 rev “A”
3) Tool drawing FAJ112W1000-1 sheet 3 rev “New”
4) Tool drawing FAJ112W1000-1 sheet 4 rev “B”
5) Tool drawing FAJ112W1000-1 sheet 5 rev “A”
6) Tool drawing FAJ112W1000-1 sheet 6 rev “A”
HAL has completed all of the fabrication and inspection operations as documented on internal work
order #1357911. HAL has determined that the 777 Left Hand Rear Spar tool (FAJ112W1000-1) is
compliant to the purchase order and the tool design requirements. The CoC encompasses all tool design
requirements; i.e., tool feature location, material(s), quantities, flag notes, special purchase items and
includes the following special processes used to fabricate the tool:
1) D32028-2 Rev. M (welding/stress relief)
2) D33181-53A Rev. A (ERS establishment)
3) D33181-40 Rev. L (tool identification)
Nonconformance:
SNN 1234567 (HAL CAR# 7654321)
Respectfully,
John Q Fab January 21, 2019
John Q Fab HAL Quality Manager Date
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Appendix A
Production Equipment and Special Tooling Quality Standard Document Map
D950-11059-1
A
S9100 D
A
S9102 B
Introduction and General Requirements
7.2 8.4
7.3 8.4.1
7.5.1 8.4.2
8.2.1
Seller Asset Capability
7.2 8.4
7.3
Configuration Management
8.1.2 8.2.1
Engineering Design/Definition
8.2.1 8.3.6
8.3
Data Elements
8.2.1 8.5.3
8.5.1 8.5.5
Fabrication, Rework, and Modification
8.1 8.5.5
8.2.1 8.5.1
8.5
Special Processes
8.4 8.5.1
8.4.2
Acceptance
7.1.5 8.5.1.1
7.1.5.1 7.1.5.2
Periodic Inspection
8.2.1 8.7
8.5.1.1 7.1.5.1
7.1.5 7.1.5.2
Each Use Condition Check
8.5.1.1 8.7
Manufacturing Work Instructions
8.1 8.5.5
8.2.1 8.5.1
Production Process Verification and Asset Relationship
8.2.1 8.6
8.5.1.3 8.5.1.1
5.2 5.5.3
5.3
Preventive Maintenance
8.1 8.7
8.2.1 8.5.1.1
Protection and Storage
8.5.1.1 8.7
8.5.4
Nonconformance
8.2.1 8.7
Potential Product Impact
8.2.1 10.2
8.7
Receiving and Shipping
8.2.1 8.7
8.2.2 8.6
8.4.3 8.5.4
Records
8.4.3 10.2
8.5.1 9.1.1
8.5.1.2 8.7.2
8.5.1.3 8.6
8.5.2 8.5.6
8.5.3
ST Use for Post-production and Spares
Applies as above
Definitions of General Terms
Applies as above
Rev G
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69 of 76
Appendix B
Document Revision Record
Rev
Sect
ion
Change
Rationale
A
Table of
Contents
Added section 1.3 and appendix B.
Improvement. Standard
technique for documenting
revisions.
Definitions
Deleted First Product Inspection, added
Periodic tool Inspection and ST Validation.
Align with IDS common
process.
Section 1
Added new section 1.3, References.
Clarification.
Section 3;
Table 1
Added provision to contact Boeing for
clarification; added “periodic” to inspection
requirements.
Clarification.
Section 4, 4.2
Added contract requirement language.
Improvement.
Section 5,
5.2, 5.2.5
Revised title and paragraph to focus requirement
at Seller level and remove from user level.
Align with generally accepted
industry practices.
Section 6, 6.2
Added requirement C.
Improvement.
Section 7, 7.2
Added delegation requirements statement
when using third party.
Clarify requirement
specifically for acceptance
delegation.
Section 8, 8.2
Added computer measurement system
requirements; added item 7, ST validation
paragraphs; deleted FPI language.
Allow usage of advanced
measurement equipment
without DPD approval. Align
with IDS common process.
Section 9, 9.2
Deleted item 8.
Align with change in 5.2.5.
Section 10,
10.2
Revised formatting; added change in MOI
designation communication requirement; added
delegation requirements when using third party.
Clarification.
Section 11,
11.2.2
Added contract compliance requirement,
change requirement; deleted item 8.
Clarification.
Section 13,
13.2, 13.2.2
Revised wording.
Clarification.
Section 18,
18.2
Added requirement to enter received ST
into Seller’s approved control process.
Improvement.
Section 19,
19.2
Added not in use to in use communication
requirement.
Process improvement.
Requirements
sections
Added alphabetical identification to each
requirement within the section.
Eliminate confusion when
referencing a specific
requirement.
Rev G
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70 of 76
Revision Letter
A
Changes in This See appendix B.
Revision
Authorization for
Release
AUTHOR:
William J. Petry
3H1
Sept 17, 2009
Org. Number
Date
APPROVAL:
Thomas J. Spiegel
D500
Sept 17, 2009
Org. Number
Date
DOCUMENT RELEASE:
Ngoc H. Bui
G-823A
Sept. 23, 2009
Org. Number
Date
Rev
Sect
ion
Change
Rationale
B
Title
Changed IDS to BDS
Update of company business
unit name
Section 1.1
Added AS9100 revision level, Rev B
Clarification
Section 1.2
Added “accountable to Boeing,” and
business unit name update
Clarification of applicability to
only those Government ST
accountable to Boeing
Section 3.2
Removed must and replaced with must
Clarification
Section 4.2.A
Added seller subcontractor controls element
Clarification
Section 5.2.1
Added instructions behind ST usage
Clarification
Section
7.2.C.2
Added computer measurement system
provision
Clarification
Section
7.2.C.4
Added authorization requirement
Clarification
Section 8.2.G
Added alternative method for evidence of
acceptance
Alignment with AS9100 Rev
B
Section
11.2.2.B.5
Removed “coordination” and replaced with
“notification”
Clarification
Section
18.2.2.C
Restructured prior to shipping requirements
from paragraph to listed requirements
Clarification
Section
18.2.2.E
Reworded requirement to “adequately
preserve and protect”
Clarification
Rev G
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Non-technical / Administrative Data Only. Not subject to EAR or ITAR Export Regulations.
71 of 76
Revision Letter
B
Changes in This See appendix B.
Revision
Authorization for
Release
AUTHOR:
William J. Petry
3H1
Oct 29, 2010
Org. Number
Date
APPROVAL:
Thomas J. Spiegel
D500
Oct 29, 2010
Org. Number
Date
DOCUMENT RELEASE:
Charlene J. Gerken
9M-ST-EUB0
Nov. 2, 2010
Org. Number
Date
Revision Letter
C
Changes in This Revised verbiage in Section 10.2 item D. 7
Revision
Authorization for
Release
.
AUTHOR:
Albert C Hodge-Jr
GT-01-3H2
Nov. 29, 2011
Org. Number
Date
APPROVAL:
Joseph K. Lonigro-III
GT-01-3H1
Nov. 29, 2011
Org. Number
Date
DOCUMENT RELEASE:
Rebecca Byers
9M-ST-EUB0
Nov. 29, 2011
Org. Number
Date
Revision Letter
D
Changes in This Added word “technical” to content owner statement on page and also
Revision added verbiage on page 1 stating Jeff Webb has RAA for ISE ownership
Authorization for
Release
AUTHOR:
Albert C Hodge-Jr
GT-01-3H2
Feb, 23,2012
Org. Number
Date
APPROVAL:
Jeff Webb
HM-01-D50A
Feb, 23,2012
Org. Number
Date
DOCUMENT RELEASE:
Charlene J. Gerken
9M-ST-EUB0
Feb, 23,2012
Org. Number
Date
Rev G
D950-11059-1
Non-technical / Administrative Data Only. Not subject to EAR or ITAR Export Regulations.
72 of 76
Revision Letter
E
Changes in This Added NEW content owner on page 1 and also
Revision added verbiage on page 1 stating Timothy R. Ditch has RAA for Quality Ownership
Authorization for
Release
Rev
Sect
ion
Change
Rationale
F
Document
Information
Added Non Proprietary statement; Add
requirement to use most current document;
Revised all instances of “shall” to “must”.
Clarification and missing
requirement; document
administration decision
Table of
Contents
Revised page numbers and added new section
references.
Required to align with added
requirement sections
Section 1.1
Removed AS9100 revision references; Added
AS9100 name; Added FAR references; Added
Mylar reference; Added ST exclusion types.
Revised All Special Tooling (ST) references to
ST acronym throughout document.
Clarification of requirements
applicability in introduction and
to maintain term uniformity in
document
Section 1.2
Revised applicability statement; revised
documentation requirements; revised
internal audit requirements; revised
surveillance and Boeing ST
determination requirements; added
Boeing provided ST definition
requirement; added data system
element; added ST usage and alternate
method requirement.
Clarification of requirements
Section 1.2.1
Added Seller subcontractor general requirements
section; added definition to flow-down
requirements to subcontractors; added Seller
responsibility for subcontractor approvals.
Clarification and missing
subcontractor control elements to
align with AS9100
Section 1.3
Added reference to Mylar controls; Add
references to unique ST form documents.
Additional control elements
identified to improve ST
documentation
AUTHOR:
Albert C Hodge-Jr
GT-01-3H2
Aug 24, 2015
Org. Number
Date
APPROVAL:
James R. Peth
HM-01-D50A
Aug 24, 2015
DOCUMENT RELEASE:
Alicia E. Otero
Org. Number
9M-ST-EUB0
Date
October 6, 2015
Org. Number
Date
Rev G
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73 of 76
Rev
Sect
ion
Change
Rationale
F
Section 2
Added Boeing Defined Definitions; Revised
Boeing-Defined ST to add ST elements; Added
Capital Equipment definition; Revised
Configuration Alignment definition; Revised
Configuration Management definition to add ST
life cycle and contract elements; Added General
Purpose Tools definition; Revised Media of
Inspection definition; Added Overhead
Mechanical Handling Equipment definition;
Added Post Production Spares definition; Added
Seller-defined definition; Added Seller Owned
ST definition; Added Shop Aid Tool definition;
Revised ST Specification definition; Added CMS
definition; revised Periodic Inspection to Periodic
Tool Inspection throughout document; Added
Special Test Equipment (STE) definition.
Required definitions to terms
used throughout the document
and clarification to existing
definitions and to maintain term
uniformity in document
Section 3.1
Revised Category I description.
Clarification
Section 3.2
Revised Category II description.
Clarification
Section 3.3
Added Boeing right of ST category determination
and buyer communication.
Clarification
Table 1
Revised Category II description; Added evidence
of ST acceptance requirement; added referred to
terminology; added Cat II requirement; Added
Cat II requirements per section 10.
Clarification
Section 4.2
Revised B. Proficiency Statement; Revised C &D
for Boeing communication requirements.
Clarification
Section 5.2
Revised Boeing communication requirement.
Clarification
Section 5.2.1
Added obtain ST definition instruction; Revised
Boeing communication. Requirement.
Clarification
Section 5.2.3
Revised Configuration elements; Revised Boeing
communication requirement.
Clarification
Section 5.2.4
Revised Boeing communication statement.
Clarification
Section 5.2.5
Revised B - for Boeing communication
requirements; Added C - added conditions for
configuration alignment, contract changes and
coordination.
Clarification
Section 6.2
Revised C – added CMS acronym; Revised D –
ST definition approval and Boeing
communication requirements; added a) & b)
element to add seller owned ST responsibility;
Added D – ST definition approval conditions;
Revised E – Tolerance requirements and added
ASME Y14.5 requirement; Revised G – changed
ST history retention requirement.
Clarification and addition of
missing control elements to align
with AS9100 and industry
recognized standards
Section 7.2
Revised B – ST work authorization requirement
examples; Added C – ST work authorization
elements; Added E – Mylar control requirement
and examples; Revised G.3 – for third party
approval and control requirements.
Clarification and addition of
missing control elements to align
with AS9100 and industry
recognized standards
Rev G
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Non-technical / Administrative Data Only. Not subject to EAR or ITAR Export Regulations.
74 of 76
Rev
Sect
ion
Change
Rationale
F
Section 8.1
Added requirements to ST Acceptance scope.
Clarification for intent of section
Section 8.2
Removed B - CMS requirements; Added new B –
including in-process and final ST acceptance
parameters, use of build records and feature
control elements. Revised C 3.- added End item
MOI and reference to section 10; Revised D –
added formal communication requirement;
Revised F 1&2- defined permanent marking;
clarified alternate marking method.
Clarification and addition of
missing control elements to align
with AS9100 and D6-51991
Section 8.2.1
Added Section 8.2.1 A thru C detailed CMS
control requirements and NADCAP recognition
requirements.
Clarification and addition of
missing control elements to align
with AS9100 and D6-51991
Section 9.2
Added E – ST definition retention and
communication requirements.
Clarification
Section 10.2
Revised and added A – Relocated and
added condition requirement from section
3 (3.2.1 and 3.2.2) rev E; Add C – Seller
determination of MOI status and
conditions; Added C conditions 1&2. –
retains ST definition; retains product
definition; Added initial MOI
determination meet section 8;PTI
exclusion process and condition
requirement; Added D - elements for out
of production spares, PTI exceptions, and
excess ST notification requirements;
Revised E – submittal of seller created
PTI plans to Procurement; Revised G & H
– Mandatory requirement to send PTI
results to procurement; Revised L – Seller
changes and Boeing determination for
PTI; Revised M 3 – For third party
approval and flow-down; Added N –
request for PTI extensions. Added
O – PTI delinquency requirements / instructions
and communication requirements.
Clarification of section scope and
intent and addition of missing
control elements to align with
AS9100
Section 10.3
Added section 10.3 – relocated
requirement from section 11.2.4 rev E.
Clarification of section scope and
intent
Section 11.2.2
Revised B- as specified by contract;
Revised B 1 – Added ST code examples;
Revised B 2 – defined basic identification
elements; Revised B 3 – Added contact
and program elements; Revised B 5 –
loose detail identification requirements;
Revised C – for Boeing communication
and identification change control.
Clarification
Section 11.2.3
Revised A – Removed “intent” and added
“developed and utilized”; Added 2.
Boeing –defined a) – verify latest TUI
usage revisions.
Clarification
Rev G
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75 of 76
Rev
Sect
ion
Change
Rationale
F
Section 12.2
Revised B – documenting tool use
instruction on planning; Revised D –
Boeing Communication requirements.
Clarification
Section 14.2
Added – maintain documented process for
ST maintenance; Revised A – clarified ST
excessive ware instructions; Revised B –
clarify formal request for ST definition;
Added E & F –Boeing communication
requirements.
Clarification and addition of
missing control elements to align
with AS9100
Section 15.2.2
Added A – contract termination,
accountability and ST excess notification
requirements.
Clarification
Section 16.2
Revised A – Added quality management
system nonconformance elements;
Revised C – Boeing communication
requirements; Revised E – Added
examples of alternate methods and
approvals; Added F – defined alternate
methods and conditions.
Clarification
Section 16.3
Revised - Added nonconformance
elements when reporting.
Clarification
Section 17.2
Revised A – added quality management
system CA investigation documentation
requirements; Added D – Boeing
notification and results requirements;
Revised F – Boeing communication
requirements.
Clarification
Section 18.2
Added C – ST must meet section 8 ST
Acceptance requirements;
Clarification and addition of
missing control elements to align
with AS9100
Section 18.2.1
Added C – ST receiving accountability
and data system update requirements;
Added D – Obtain ST definition when not
received with ST as part of receiving insp.
Clarification and addition of
missing control elements to align
with AS9100
Section 18.2.2
Added C – ST subcontractor shipping
accountability and data system update
requirement; Revised D.2 to add
mandatory examples; Revised E –Submit
nonconformance prior to shipping;
Revised H 1 thru 6 – shipping question
clarification; Added - Obtain Boeing
authorization to ship ST without
definition.
Clarification
Section 19.2
Revised C – added PTI and contact
requirement; Revised D – defined post
production process requirements, obtain
ST definition and Boeing communication.
requirements
Clarification
Appendix A
Revised AS9100 and AS9102 to align
with Rev F.
Clarification to AS9100 and
AS9102
Rev G
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Non-technical / Administrative Data Only. Not subject to EAR or ITAR Export Regulations.
76 of 76
Revision Letter
F
Changes in
This
See appendix B.
Rev
ision
Authorization
for
Release
AUTHOR:
Greg W. Schmid
HM-01-D78A
June 13, 2016
Org. Number
Date
APPROVAL:
Timothy R. Ditch
HM-01-D78A
June 13, 2016
REVIEWER:
Lucia Casillas
66-CJ-MP6Q
June 16, 2016
Org. Number
Date
DOCUMENT RELEASE:
Alicia E. Otero
9M-ST-EUA0
June 21, 2016
Org. Number
Date
Revision Letter
G
Changes in
This
Complete rewrite to combine contractual requirements for the creation of one contract
Revision document for BDS and align with BCA and BGS Enterprise requirements. Retains all
original requirements (new through revision F). Includes realignment, restructure,
additional/revised terminology and expanded requirements for Production Equipment and
Special Test Equipment (STE).
Authorization for
Release
AUTHOR:
Greg W. Schmid
327489
Name
BEMSID
HM-01-D77A
May 03, 2021
Organization Number
Date
APPROVAL:
Timothy Ditch
327398
Name
BEMSID
HM-01-D77A
May 03, 2021
DOCUMENT RELEASE:
Organization Number
Date
DOCUMENT RELEASE:
Name
BEMSID
DOCUMENT RELEASE:
Organization Number
Date
Heather J. Kinney 3315235
9M-ST-EUA0 May 14, 2021
