Value-Added Aerospace Auditing Workshop

1. WELCOME! Americas Aerospace Quality Group AAQG Registration Management Committee RMC Auditor Training and Workshop Session Minneapolis, MN July 30-31, 2009 Value Added Aerospace Auditing

2. Robust Auditing of Internal Audits Presented by Stanley M. Faust, Spirit AeroSystems

3. Objectives The focus and purpose of this presentation is to facilitate the discussion relative to the dynamics and challenges contract auditors face while assessing an organization’s internal audit program

4. Agenda • 9100 Criteria • Planned Intervals • Covers all system requirements • Implementation and maintenance • Audit program • The procedure • Corrective action • Detailed tools and techniques • Contractual and regulatory requirements • The results

5. 9100 Criteria 8.2.2 Internal Audit: The organization shall conduct internal audits at planned intervals to determine whether the quality management system a) conforms to the planned arrangements (see 7.1), to the requirements of this International Standard and to the quality management system requirements established by the organization, and b) is effectively implemented and maintained. An audit program shall be planned, taking into consideration the status and importance of the processes and areas to be audited, as well as the results of previous audits. The audit criteria, scope, frequency and methods shall be defined. Selection of auditors and conduct of audits shall ensure objectivity and impartiality of the audit process. Auditors shall not audit their own work. • How about: • Ensures conformance • Measure and Monitor the system health • Provides continual improvement focus areas • Identifies training needs • Eliminates the use of “tribal knowledge” • $$$ Identifies Waste How do internal audits “Add Value” ?

6. Planned Intervals • The schedule must be adhered to and adjusted as needed. (results, completions, customer feedback). • All requirements must be covered i.e. contractual, regulatory, planned arrangements and QMS. • Is the plan effectively implemented and maintained • Process based • Types of nonconformities • Basic • Meaningful

7. The Internal Audit Procedure • Auditor Competence • Scheduling • Defined responsibilities for planning the audit • Conducting the audit • Reporting results in a timely manner • Corrective Action and Verification (Closed Loop) • Records must be maintained • 4.2.4

8. Corrective Actions • Area management responsibility • Actions are taken without delay to eliminate nonconformities • Identify root causes • Follow-up • Verify actions taken are effectively implemented • Reporting of verification results • Responses must be on time • Are nonconformities tracked and analyzed for trends • How are recurring nonconformities addressed • 8.5.2 Reminder: Auditors and Organizations can find corrective action guidance in the SCMH Reference Chapter 9.0 9.1 Root Cause Analysis and Problem Solving (01 Oct 2008) 9.1.1 Root Cause Analysis and Problem Solving Model Introduction 9.1.2 Root Cause Analysis and Problem Solving The 9-Step Process

9. The Audit Tool Box • In order to conduct an “effective” internal audit an organization must have audit tools. • These tools i.e. checklists, process flow charts must developed and implemented prior to audit conduct. • They should avoid the use of generic or designed to fit individual audits (process specific)

10. Results • There should be no “soft grading”. Organization should define nonconformance vs. opportunity for improvement. • Once the audit is complete, the organization • Summarize results • Document Findings • address performance problems • Identify opportunities for improvement • The results of the audit must be one of the inputs of the organization’s Management Review process. • The analysis of data must be used to drive continuous improvement (AS9100 5.6.2, 8.4)

11. Aerospace Auditor Reminders • When auditing this process.: • Process is in place. • Do not allow for a one time event. • Review current and past schedules (slides, required audits not complete) • Process focus • Check sheet driven audits are not effective. • 4.2.4

12. Questions