What are the most important quality assurance metrics for aerospace manufacturing?

Engineers need to ensure that every part produced will perform consistently and reliably to the requirements of the application, which necessitates that components be held to rigorous standards, testing and inspection, in order to verify proper functionality and to ensure safety is prioritized. Manufacturers who demonstrate that they are in compliance with ASD9100D can also demonstrate compliance with the broader ISO 9001 standard (which the AS9100 quality management system contains in its entirety). Manufacturers also need to consider ASA-100 certification, a standard that complies with FAA Advisory Circular 00-56. Aerospace components being critical must tested for material specification, quality, safety, and functional performance.

In my experience an important step towards effective QA to support Aerospace requirements is defined, monitored and controlled processes in all organisations aspects. Each process should have SIPOC analysis and Quality Plan (QP) to support the Aerospace / Customer requirements. The QP should be based on FMEA and Taguchi analysis, implemented and verified respectively with any organization’s / processes / product changes. (FFF). This is a basic step twards building reliable QA to support Aerospace needs and Customer requirements.

Ensuring compliance with industry-specific regulations and standards such as AS9100 (aerospace quality management system standard) and FAA (Federal Aviation Administration) requirements.

To answer specifically to the question related to the most important quality assurance metrics for aerospace mfg, I will consider the following: FTQ: 100% compliance Process capability >1.67 Quality laboratory dimensional analysis control: 100% Audit Non conformances: 0 Employee engagement improvement ideas: 100% Process control: 100 % Calibrated PY on every work station: 100 % 5S program: 100 % compliance Incoming Raw material :100 % compliance Supplier audits: 100 % compliance The most important thing is that the organization needs to have their organizational culture that promotes the customer delight, empowerment, open communication and anticipating the customer needs. Follow their mision and vision as well.

Composites have played essential role in aerospace structures including the internal and peripheral components. Thermosetting and thermoplastic polymers have been used as the composite matrices. The most successful fillers used in aerospace materials are fibers. Polymer/fiber composites exhibit improved mechanical properties, thermal constancy, wear resistance, chemical resistance, anticorrosion, and nonflammability performance. Aerospace materials are frequently metal alloys, although they also include polymeric based materials, that have either been developed for aerospace purposes. Aerospace require material with exceptional performance, strength, heat resistance, even at the cost of high for their fabrication or conventional machining.

The Aerospace Standards are a series of quality standards based on ISO 9001 and developed by the International Aerospace Quality Group (IAQG) to provide international consistency regulatory, safety and reliability requirements. Materials for aircraft manufacturing, including its' strength, density, malleability and ductility, elasticity and brittleness, toughness, and fusibility. Nickel-, cobalt- , titanium and iron-based superalloys provide high strength and corrosion resistance at elevated temperatures, making them ideal for hot applications in jet engines. Certain alloys have great strength and stiffness and are used for landing gear and frame structures. Most airplanes are made out of aluminum, a strong, yet lightweight metal.

Quality management for an aerospace manufacturing company firstly means improving the processes with industry-regulated best practices. It helps in streamlining the production processes making them consistent and timely. Manufacturing and assembly processes must also be monitored to ensure that they adhere to strict quality standards. This includes regularly inspecting parts, conducting tests, and analyzing data to identify areas for improvement. Organizations must also develop procedures for managing any non-conformances that are identified during the production process to prevent their recurrence. Production processes are checked for conformance, consistency, capability, be improved on the basis of feedback mechanism and lesson learned.

Aerospace standards testing ensures companies from around the world can test their products and evaluate their mechanical, thermal, electrical, optical and chemical properties. In aircraft manufacturing, quality control and assurance is of the utmost importance. Manufacturers are required to document, track, inspect, and reinspect all items and phases of a build to build evidence that everything is completed to very strict standards. In manufacturing, quality control focuses on parts meeting specifications and tolerances. QC ensures engines, drive trains, and other mechanical parts operate smoothly, efficiently, safely, and as designed. Testing quality emphasizes the roles of R & D, product design, and development for defect free operation.

Quality management in aerospace sector is more complex than any industry. It should result in efficient processes, quality components and assemblies, industrial compliance, continual improvement and higher customer satisfaction. Hence, quality management should not be just regarded by the aerospace manufacturers as a mere formality to sustain in the industry. It is quite comprehensive involving numerous critical aspects and that is why the AS9100 standard was formulated. It intends to help aerospace manufacturers and distributors to adopt the best practices for ensuring quality management and the safety of consumers.

In quality management, one key aspect I have found to be important and useful is people training. Sometimes there is a gap between the quality standards set by an organization and the knowledge of people involved in the processes. This gap can be lessened by regular training and drawing a questionnaire for the employees to assess the knowledge of the team.