SUPPLIER SOURCE SUBSTANTIATION
Specification Number: S-1001
Issue Date : 10/30/2009
This specification is in addition to and in no way limiting, superseding, or abrogating any contractual obligation as required by the applicable procurement document.
Table of Contents
Source Substantiation Process Map
A Source Substantiation
B Requirements for Category I Classification
This specification defines requirements for the Source Substantiation process for GE – Aviation Suppliers and Revenue Share Participants (RSP).
SOURCE SUBSTANTIATION PROCESS MAP
Initiate GT7350 for Manufacturing Source
Apply Engineering Requirements
Apply Quality Requirements
Apply MAE Requirements (as required)
Create IMPACT Quality Plan for the PO/PA Source
Engineering Review & Approval
Provide Source Substantiation Data
Serial/Lot Number Approval (optional)
Quality Review & Approval
Update Digital Workbench for Approved Source of Manufacture
MAE Review & Approval (as required)
Update IMPACT Quality Plan for the PO/PA Source
1.0 The Source Substantiation process is required on Production and Class Y parts that include an Aviation drawing note "Vendor Substantiation Required" or "Vendor Substantiation Required for this Assy and for Certain Components”, and the applicable AVIATION Purchase Order (PO) or Purchase Agreement (PA) imposes this document (S-1001) and P1TF17 AVIATION SPECIFICATION “SOURCE SUBSTANTIATION ADMINISTRATIVE REQUIREMENTS”, ref. Appendix A.
2.0 For Aviation drawings that include the note "Vendor Substantiation Required for Certain Components of the Assy", only the component drawings within the assembly that include the "Vendor Substantiation Required" note require Source Substantiation.
3.0 Aviation drawings that include the Vendor Substantiation note for parts ordered as Engineering Class L or F parts do not require Source Substantiation.
4.0 Source Substantiation requirements for RSP product, where AVIATION has delegated design responsibility to the RSP, are defined in S-477 AVIATION S-SPECIFICATION “QUALITY REQUIREMENTS FOR RSP’s WITH DESIGN RESPONSIBILITY”. RSP items supplied or manufactured to Aviation drawings must comply with this specification (S-1001).
5.0 The GT7350, herein referred to as the Source Substantiation Plan (SSP) in the Electronic Vendor Substantiation System (eVSE), will be used for; New Parts, Source Changes (includes alternate Sources), Process Changes, Rework, and Administrative Changes.
1.0 SSP Initiation
For New Parts and Source Changes the originator (e.g. Aviation Sourcing, Sourcing Quality, Engineering, etc.) initiates GT7350, herein referred to as a SSP, and forwards the SSP to the Engineering function.
For Process Change and Rework requests, the Supplier will originate and forward the SSP to the Aviation Sourcing or Quality Representative prior to implementing the change.
Changes in Design (CID) must be evaluated by the Supplier for potential impact on significant operations and their sequence to determine if a Process Change SSP is required.
Changes of sub-tier Sources for a significant operation, where the sub-tier does not manufacture the VSE required part complete, are considered Process Changes not Source Changes, e.g. changing heat treat sources.
The Source information entered on the SSP, including the Source’s Commercial and Government Entity (CAGE) code, will be the Source that manufactures the VSE required part complete.
For Suppliers identified as Supplier Design Integrators, the Supplier entered on the SSP will be either the Supplier Design Integrator or the Source that manufactures the part complete.
1.5 Administrative Change SSP’s, or changes that do not exceed the approved process limits, do not have to be submitted for approval, but must be documented and maintained on file at the Supplier. The Supplier must assure that the change meets the definition of Administrative prior to selecting that type of SSP.
2.0 Application of Requirements
2.1 The Aviation Engineering function will establish the Engineering requirements, with input from the Materials Application Engineer (MAE) as required, and forward the SSP to the Aviation Quality Representative.
2.2 The Aviation Quality Representative establishes the Quality requirements and forwards the SSP to the Supplier.
2.3 For New Parts, Source Changes, and Rework (if there is a part number change), Aviation Sourcing will incorporate the SSP requirements on the PO/PA and forward the SSP to the Supplier.
2.4 For New Part, Source Change, and Rework (if there is a part number change) type SSP’s, the Aviation Quality Representative will create a Quality Plan in IMPACT for the Supplier listed on the Aviation PO/PA.
3.0 Source Substantiation Data (SSD)
3.1 The Supplier will complete the Engineering and Quality requirements and include objective evidence in the SSD section of the SSP. The Supplier will forward the SSP to the Aviation Quality Representative for review, including the proposed list and sequence of significant operations.
3.2 Reference S-478 AVIATION S-SPECIFICATION "SOURCE SUBSTANTIATION FORMAT - STRUCTURES CoE AND COMBUSTION CoE" and S-404 AVIATION S-SPECIFICATION "SOURCE SUBSTANTIATION AND PART CUT-UP DATA PACKAGE" for recommended formats to organize SSD for a SSP.
4.0 Quality/Engineering Review and Approval
4.1 The Aviation Quality Representative will review the SSD for accuracy and completeness, including the proposed list of significant operations, resolve Supplier issues as required, and, if acceptable, approve the SSP for Quality. The Quality Representative will forward the SSP to the Aviation Engineering function.
The Aviation Engineering function, in conjunction with the MAE as required, reviews the SSD and, if acceptable, approves the SSP. Full SSP approval of the production process must be complete prior to shipment of VSE required items to Aviation, except as noted in Section V.6.0 Approval by Serial/Lot Number.
For New Part and Source Change type SSP’s, an approved Aviation Engineering or Quality function, or the eVSE System, will update the Digital Workbench (DWB) for the approved Source that manufactures the VSE required part or component.
The Aviation Quality Representative will update the IMPACT Quality Plan for the Supplier listed on the Aviation PO/PA.
Aviation Sourcing, or the eVSE System, will notify the Supplier of SSP approval prior to shipment of the parts from the Supplier.
V. OTHER REQUIREMENTS
1.0 Raw Material Testing
1.1 Raw material testing of Source Substantiated product will be performed per the requirements of S-1000 AVIATION S-SPECIFICATION “AVIATION QUALITY SYSTEMS REQUIREMENTS FOR SUPPLIERS” and any additional requirements that may be specified by AVIATION on the SSP.
1.2 Certified Laboratory Testing Applicability for Source Substantiation required product:
1.2.1 The following items do not require testing at AVIATION approved laboratories, including any other exceptions defined on the SSP.
184.108.40.206 Processing materials or consumables such as tungsten electrodes, brazing flux, stop-off material, grit blast and shot peen media, solvents for cleaning, inert gases (used for heat treatment, brazing, and welding), chemical processing solutions (i.e. acid activation, etching, anodizing, plating, conversion coating, stripping and cleaning solutions), and are not considered raw material.
220.127.116.11 Dry Film Lubricants
18.104.22.168 Primers, excluding primers used for adhesive bonding
22.214.171.124 Residue from cleaning, inspection processes, or masking materials
126.96.36.199 Composite material tracer yarn, hot melt resin for tacking, and non-structural foam
2.0 Post VSE Review (PVR)
2.1 PVR Applicability
2.1.1 Candidate parts for a PVR are VSE required parts that are new or transferred from one manufacturing Source to another.
2.1.2 Part number changes on hardware in production at the same Source are not considered new and do not require a PVR, unless the original configuration required a PVR before the part number changed and the PVR was not completed.
2.1.3 Parts identified as Priority Parts do not require a PVR (ref. S-1000 for PPR requirements).
2.2 The Supplier will conduct the PVR 6-24 months after initial SSP approval, using the PVR Checklist located on the AVIATION Supply Chain Web Center, under Audits > Checklist when required by the SSP or as directed by the AVITAION Quality Representative. The AVIATION Quality Representative may, based on availability of the parts, modify the time period between initial SSP approval and the PVR. The review will be conducted at the Supplier and may include participation by AVIATION representatives.
2.3 The Supplier will provide documents necessary to support the review process and will complete actions identified during the review.
3.0 Certification of Special Processes
3.1 When certification or qualification of equipment, processes, operators or inspectors is required by specification (or other referenced documents), the Supplier will assure certification is complete and documented for both in-house and sub-tier sources.
3.2 Special Processes will be certified when used on Source Substantiation required parts or components. The Purchaser will designate each Special Process as Category I or Category II for each Supplier. Category I indicates that the Supplier is authorized to approve other Sources of that Category I Special Process. Approval as a subtier to a Category I supplier does not infer approval to accept GE work from GE or from other GE Suppliers. Acceptance of such work requires additional approvals. See Appendix B for classification requirements for Suppliers of Category I Special Processes. Any Supplier that has been designated as Category I (prime or sub-tier) cannot extend AVIATION Category I status to any other Source.
3.3 For Supplier designed items, certification of Special Processes is required for:
3.3.1 Special Processes listed on the Source Substantiation Listing (SSL).
Non-destructive testing processes listed on the SSL.
Metallic and/or non-metallic material testing laboratories when the material specification is listed on the SSL.
3.4 The Purchaser will document categorization and specific approvals for a Supplier of Special Processes. Categorization is subject to change depending on the degree of compliance when compared to the Purchaser's assessment criteria.
3.4.1 Supplier corporate entities, that have been granted Category I status for Special Processes, may extend the use of their approved Special Process Source(s) to any of their own corporate subsidiaries.
The following minimum requirements will apply:
188.8.131.52 The corporate entity will be responsible for the proper identification and technical control of the Special Process Sources used by their subsidiaries.
184.108.40.206 The corporate entity will maintain and provide a current listing of their approved Special Process Sources to their respective subsidiaries.
220.127.116.11 The subsidiaries will identify the approved Special Process Source(s), selected for use, on the manufacturing or quality planning.
18.104.22.168 The subsidiaries will define the methods of control in the subsidiary quality manual, procedure, or work instruction that relates to Special Processes, requirements, responsibilities, etc.
3.4.2 For Special Processes on Source Substantiation required items, and when the Purchaser has granted a Supplier Category II status for a Special Process(es), the following requirements apply.
22.214.171.124 The Supplier will use Special Process Sources certified by the Purchaser. A list of certified Sources of Special Processes is maintained in the “Yellow Pages” on the AVIATION Supply Chain Web Center (SCWC).
126.96.36.199 Requests for certification of a new Special Process Source may be proposed to the Purchaser, subject to review and approval by the Purchaser prior to use and addition into the “Yellow Pages”.
188.8.131.52 The certification of sources by the Purchaser assures potential capability of the Sources but does not guarantee continued satisfactory performance. Purchaser certification also does not constitute Source Substantiation approval. The Supplier will have responsibility for their purchased services and materials.
184.108.40.206 AVIATION sites are considered a “Yellow Page” source when material is returned to AVIATION by direction of the Purchaser for the application of Special Processes.
220.127.116.11 For Supplier designed items; the Supplier must use “Yellow Page” sources for processes identified on the SSL.
Suppliers will maintain a list of Special Process Sources used, and assure those Sources are certified by the Purchaser prior to use.
The Purchaser subscribes to Nadcap. The list of special processes for which the Purchaser requires and recognizes Nadcap accreditation is available on the SCWC. Suppliers seeking certification by the Purchaser for these special processes are required to obtain Nadcap accreditation in advance of a GE initial audit. Ongoing surveillance is required through Nadcap. The Purchaser reserves the right to waive this requirement in part or in whole at its sole discretion.
3.5 For Special Processes on Source Substantiated hardware, S-400 AVIATION S-SPECIFICATION “Certified Materials Test Laboratories (CMTL): Metallic Materials” and S-450 AVIATION S-SPECIFICATION “CERTIFIED MATERIALS TEST LABORATORIES (CMTL): NON-METALLIC MATERIALS”, certified laboratories are required, except for coatings, which must meet the requirements of S-459 AVAITION S- SPECIFICATION “COATINGS EVALUATION LABORATORY AND PERSONNEL ACCREDITATION PROGRAM REQUIREMENTS”.
4.0 Distributors: Suppliers identified as Distributors in the AVIATION SCWC Source Profile system must comply with S-411 AVIATION S-SPECIFICATION “PROCUREMENT AND CONTROL OF SOURCE CONTROL HARDWARE FROM A DESIGNATED DISTRIBUTOR”, and flow down the requirements of this specification (S-1001) and S-411 to manufacturers of Source Substantiation required items.
5.0 Significant Operation/Sequence Changes
Temporary changes that affect significant processes, including rework procedures, do not include Material Review Board (MRB) repair methods that have been approved through the MRB system. A Process Change type SSP must be created the first time a rework procedure is used if:
The significant operation(s) in the rework procedure are outside the VSE approved process limits
The rework procedure uses the same approved VSE process but is subsequently used on material in a different starting condition
The rework could affect drawing or specification process or property requirements based on the number of times the rework procedure is used (i.e. accumulated time at temperature).
5.2 Occasionally, an unintentional or inadvertent change in a sequence/process may affect a limited number of parts. These parts must be identified on a SSP and restricted from shipping until the SSP is approved. However, if the sequence/process change results in a drawing nonconformance then the parts must be referred to MRB for disposition and a SSP is not required.
6.0 Approval by Serial/Lot Number
Approval of selected Serial or Lot numbered parts (herein referred to as Serial Number or SN) may be used after all SSP requirements are complete and when it is in the best interest to delay full Source Substantiation approval while the manufacturing process is being developed and evaluated by the AVIATION Engineering and Quality function. The Engineering function may modify the initial SSP requirements to accept selected parts by SN, for use without restrictions, provided the modifications are documented in the SSP for the affected SN’s. See Figure A “SN/LN Approval Process Map”.
The AVIATION Engineering function may grant Full Approval when the Source has presented documented evidence that the process has been developed and satisfactorily meets all the SSP requirements.
6.3 The Purchaser will determine when the SN process may be used and the Supplier must have a system to prevent shipping unapproved parts or groups.
Approval by SN must not compromise hardware integrity, quality, or the ability to meet design requirements or intent. Parts approved by SN must be acceptable for use without restrictions.
If at the desired time of part shipment, all Engineering and Quality requirements on the SSP are not complete by the Source, and the Engineering function determines that the initial SSP requirements can not be modified for the selected parts, then the selected parts may be partial released from the Supplier with prior authorization from the Aviation Quality Representative. The SN release process will not be used to partial release the selected parts, although the Aviation Engineering and Quality function may later authorize use of the SN release process if required.
6.6 The rationale for using the SN release process will be documented in the SSP.
6.7 For parts that are not serial or lot numbered, temporary numbers must be assigned and marked on the parts (or tag, if size dictates), to assure release of approved parts only. The temporary traceability marking to be applied to the parts or package tag must be specified on the SSP SN section.
6.8 Engineering may approve and close a SSP for only the SN’s listed in the SSP. A separate SSP will be required if a production process is developed at a later time.
Full Approve SSP
Ship parts Partial Release
Ship parts Full Release
Approve parts by SN/LN
Requires prior Aviation
Quality Rep Approval
Requires documentation of modified requirements in the SSP.
Requires prior Aviation
Quality Rep Approval
Serial/Lot Number Approval Process Map
7.0 Source Substantiation Control of United States Army Flight Safety Critical Parts (AFSP)
7.1 For AVIATION drawings that reference “U.S. ARMY FLIGHT SAFETY PART” and P1TF94 AVIATION SPECIFICATION “SOURCE REQUIREMENTS FOR THE U.S. ARMY FLIGHT SAFETY PARTS PROGRAM”, the following definition replaces the definition of a significant process in P1TF17 and this specification:
7.1.1 Significant Process – Any process, or element of a process, that generates a drawing critical characteristic, and/or a process that if changed could affect design intent, might affect; material structure, mechanical, chemical, or electrical properties; and cannot normally be evaluated without destructive testing.
8.0 Re-Qualification of VSE Parts
8.1 If a VSE part has not been in production during any 36 consecutive months after initial SSP approval at a Source then:
8.1.1 The Source will notify the AVIATION Quality Representative prior to re-starting production, to determine if, and to what extent, additional qualification and/or testing may be required.
8.1.2 The Aviation Quality Representative will consider any changes to the Source’s facility, process, personnel, and any drawing changes during the period of inactivity as potential factors to determine if a new SSP will be required.
9.0 Drawing and specification characteristic data results, if required by the SSP, do not have to be included in the SSD if the results are included in the electronic Characteristic Accountability and Verification (eCAV) system. The associated eCAV reference number must be included in the SSD.
This Appendix summarizes the requirements of P1TF17 and prescribes the procedure to establish a Supplier as an approved source for the applicable component or item. Requirements are also listed for any proposed change to a process or sub-tier source.
2.1.1 Specification P1TF17 identifies typical processes considered significant; that is a process that if changed, could affect material structure, mechanical, chemical or electrical properties and cannot normally be evaluated without destructive testing and could affect design intent.
2.1.2 The AVIATION PO/PA will specify requirements such as; processing documentation, inspection reports, lists, or other information required for evaluation by AVIATION prior to granting full Source Substantiation approval.
2.1.3 All data requested for submittal to AVIATION for the review and approval process must be transmitted electronically and attached in the eVSE system unless the AVIATION Quality Representative approves specific alternate arrangements.
2.1.4 Initial documented Source Substantiation approval, by part number, is granted by AVIATION on the SSP. This approval is a separate and distinct approval, not to be confused with a special process certification. When performing a significant operation involving a Special Process, Source Substantiation approval for the specific drawing application and Special Process certification are required.
2.1.5 A SSP will be initiated to obtain Purchaser's prior approval of changes to significant processes, significant process sequence, and sub-tier sources of significant processes. Approval will be indicated on the SSP.
Note: Changes made for clarification (e.g., clerical, administrative, adding a sketch/note, etc.) or changes that do not exceed the approved process limits, do not need to be submitted to the Purchaser, but will be maintained on file by the Supplier for Purchaser review.
2.2 Supplier Designed Components
2.2.1 The Supplier will prepare and maintain a Source Substantiation List (SSL) of Supplier-designed components that require Purchaser approval. The SSL will be submitted prior to manufacture of component or item unless otherwise specified by the PO/PA. The SSL, when approved by the Purchaser, permits the Supplier to operate within its scope by defining which components and processes require Purchaser's approval prior to change.
18.104.22.168 The Purchaser will determine the acceptability of a SSL that has been issued for initial approval or for subsequent significant change approval(s) and will notify the Supplier on a SSP.
22.214.171.124 If a significant process is sufficiently defined and controlled on a Supplier drawing or specification to reasonably assure that the component will satisfy its design intent, then the process does not need to be included on the SSL.
2.2.2 After Purchaser’s initial approval is granted on the SSP, the Supplier will obtain Purchaser’s approval of all subsequent changes in significant processes, significant process sequence, or sub-tier Suppliers contained in the SSL. Purchaser's approval must be received prior to implementing changes.
2.2.3 Request for approval of changes will be made by the Supplier initiating a SSP.
126.96.36.199 The Supplier is permitted to incorporate non-significant changes in processes or in sub-tier Suppliers not contained in the SSL, or portions of processes in the SSL not identified as significant, or when the change meets the definition of an administrative change without approval from the Purchaser, provided it does not change from a non-significant to a significant process.
2.3 AVIATION Designed Components
2.3.1 The Supplier will provide Source Substantiation data and documentation as required by the PO/PA. Usually this will include routing sheets with significant operations and services identified, and process sheets for each operation identified as significant. Additional dimensional and/or laboratory test results may also be required.
2.3.2 After Purchaser approval is granted on the initial SSP, the Supplier will obtain Purchaser's approval of all subsequent changes in significant processes, significant process sequences, or sub-tier Suppliers listed on the SSP. Purchaser's approval must be received prior to implementing changes. Request for approval of changes will be made by the Supplier initiating the SSP. Purchaser's approval of the requested changes will be returned on the SSP.
2.4 Source Substantiation Records
Purchaser approvals on the SSP and copies of all other required SS data and documentation (such as routers, process sheets, dimensional and laboratory results, etc.) will be maintained as part of the product acceptance record requirements of S-1000. The Supplier’s Quality function will maintain these records under their control, or specifically delegate this responsibility, to assure retrieval when required.
REQUIREMENTS FOR CATEGORY I CLASSIFICATION
1.0 TECHNICAL PERSONNEL
1.1 A list of Supplier technical personnel responsible for the control of internal and external special processes will be maintained by the Supplier and provided to Aviation upon request. Qualifications for technical personnel for each special process, as a minimum, include:
1.1.1 Two years experience and/or equivalent training in the appropriate process.
Note: Training will include certification of personnel to their specific level of qualification when required by the applicable Special Process specification.
1.1.2 Knowledge of process parameters and process control.
1.1.3 Knowledge of the effect of the process variables on the properties of the part.
1.1.4 Familiarity with contents of controlling documents including engineering drawings, specifications, operating instructions and shop practices.
1.1.5 Knowledge of the safety procedures for the process.
1.2 The authority and responsibilities of the technical personnel will be documented. Responsibilities will include approval and audit of sources, processes, personnel and equipment.
1.2.1 Technical plans, when required by an AVIATION specification, require approval by AVIATION approved Certifying Agents.
1.3 In the event that Supplier technical personnel are re-assigned, the Supplier will identify replacements to be assigned within 90 days. The Supplier will provide information regarding qualification of proposed or current technical personnel when requested by Aviation. Supplier technical personnel are subject to disqualification by Aviation.
2.0 IDENTIFICATION OF APPROVED SOURCES
2.1 A current list of approved Special Process sources, both internal and external, will be maintained by the Supplier. The list will include the Source name, address and the specific processes for which the source is approved. The list will be made available for AVIATION review on request.
2.2 The prime Supplier will have a system to assure use of only approved Special Process Sources.
2.3 Internal and external Special Process Sources will be notified of approval and the time period of approval. A letter or a certificate will communicate the notification.
3.0 AUDIT PROGRAM
3.1 A documented Audit program will be in place for Special Process sources both internal and external. The criteria for initial Source approval, continuing approval, disqualification, and the notification process for each condition will be defined by the Category I Supplier.
Audits must be performed on-site at the Supplier where the Special Process is performed.
Exceptions to on-site audits will be permitted for sub-tier Special Process Suppliers if all the following conditions are met:
The Category I Supplier is a subscribing Prime or Associate Prime member of Nadcap.
The Category I Supplier must have access to audit reports and findings from Nadcap audits performed at subtiers. Objective evidence of this access will be provided to GE-Aviation representatives upon request.
The Category I Supplier technical representative for the Special Process has conducted an initial audit on-site at the sub-tier Supplier.
The sub-tier Special Process Supplier must maintain Nadcap certification for the process.
3.2 Category I Supplier technical personnel responsible for Special Process control will complete the initial audit and approval of Special Process sources. Supplier designees may conduct subsequent audits provided the designee(s) have been trained by the technical personnel.
3.2.1 The training must be documented and will contain the following criteria as a minimum:
A provision to assure that the trainee is knowledgeable of process parameters and process control.
A provision to assure that the trainee is knowledgeable of the effect of the process variables on the properties of the part.
Provisions to assure that the trainee is familiar with contents of controlling documents including engineering drawings, specifications, operating instructions and shop practices.
A provision to assure that the trainee is knowledgeable of the safety procedures for the process.
Provisions to assure that technical personnel and trainees will perform audits to a controlled checklist. The checklist must include AVIATION Special Process checklist guidelines as a minimum. Non-Destructive Evaluation auditors will require certification per NAS410 or equivalent.
3.2.2 The criteria for audit frequency will be documented. The period between audits must not exceed three (3) years.
188.8.131.52 Excluded from this frequency are newly approved Special Process Suppliers, which will be audited no later than one (1) year after the completion of their initial audit.
3.2.3 The depth of the audit will be defined in an AVIATION audit checklist or an equivalent document.
3.2.4 Audit findings and corrective actions will be documented. Audit reports and associated documents will be retained for at least the last two audits per Source and/or Special Process(s).
3.2.5 An up-to-date audit schedule will be maintained. The schedule will include, as a minimum, Source name, last audit date, next audit date, and identity of the auditor.
4.0 OTHER SURVEILLANCE
4.1 A system will be in place to document and monitor Special Process faults or defects, and to assure effective corrective action.
4.2 A documented process control testing program must be completed and performed as part of the Special Process Source approval and in conjunction with periodic audits. When testing involves a laboratory, the laboratory must be S-400 or S-450 (as applicable).
5.1 Initial AVIATION approval to function as a Category I prime Supplier will be granted on a process-by-process basis after on-site evaluation by AVIATION approved personnel (Quality Representative/Auditor/Certifying agent). Approval will be documented designating Category I status and the Special Process approved. Continuing approval will be based on delivered quality performance and compliance with AVIATION assessment criteria (S-1000 and S-1001). The period between audits will not exceed three (3) years. Systemic noncompliance to these requirements will result in Category I removal of the process affected.
The following Special Process codes require use of an AVIATION "Certified Source" and therefore can not be issued Category I status: AF, AJ, AL, AS, AT, EG, EH, EI, EJ, GA, GB, GC, GD, and GE.
The following Special Processes may be considered for Category I status with limitations: AA, AB, AC, AE, AI, AP, AR, and AU. Approval of AC and AI is limited to the specific S-400 codes identified on the GT193.
Approval for Category I status may be limited for use of in-house or sub-tier approvals based on the AVIATION assessment. The AVIATION Special Process Certification (GT193) will document all limitations in the remarks section.
The technical representative for code DF (thermal spray) requires the approval of an AVIATION Certifying Agent per P28TF6 AVIATION SPECIFICATION “THERMAL SPRAY SUPPLIER QUALIFICATION” (ref. Para. 1.2 – Definitions).
5.2 In the absence of specific AVIATION requirements, Military or AMS Specifications (or equivalent standards) will be used as a baseline for Special Process control.
5.3 When Category I status has been obtained, the AVIATION approved "Yellow Page" sources may be used as an option. Periodic sub-tier (on-site) Special Process audits are not required if an approved “Yellow Page” source is used.
5.4 The prime Supplier has the responsibility to review the monthly deletions and additions to the "Yellow Pages", sent to the Supplier Quality Manager listed in the Supplier’s Source Profile located on the AVIATION SCWC. Use of "Yellow Page" sources does not remove the responsibility of the prime Supplier to insure the applicable process/product meets all drawing and specification requirements.
5.5 For those Special Processes that the Purchaser has granted Category II status, the Supplier will maintain a list of Sources used and assure those Sources are certified by the Purchaser.
Administrative Change: A change to a process document, which is clerical in nature and does not change the chemical, electrical, physical properties, or performance of the component or any of its parts or materials. The following are examples of changes to significant processes/sequences that are not considered significant.
A change made for clarification only (i.e., clerical or adding a sketch or note)
A change to a process requirement/parameter that stays within the currently approved SS process limits.
A change to a portion of a process or sequence that has been previously identified as not significant.
A change in sequence where two significant non-conventional machining operations that are performed in sequence (back to back), using the same process, are interchanged. For significant changes, see the definition of Significant Process/Sequence Change.
Approval by Serial/Lot Number: The Source Substantiation approval of specific serial/lot numbers that initially satisfies engineering requirements, but which requires further development of significant processes.
Approved Source: A source whose part has satisfactorily met the applicable Source Substantiation requirements and has been approved by Engineering or their delegate. Approved part/source combinations are listed in the Source Substantiation Master List (SSML) in the AVIATION Digital Workbench (DWB).
Category I - Prime and sub-tier sources of Special Processes who have the resources; namely, approved technical personnel, record keeping procedures, incoming inspection criteria of purchased services or products and overall assurance plans for adequate appraisal of quality. If these criteria are met, the Supplier may be classified Category I (qualified to conduct certification of Special Processes, both in-house and/or purchased). This process specific classification requires certification by the Purchaser.
Category II: Prime and sub-tier sources of Special Processes who DO NOT have the resources needed to qualify as Category I, will be classified Category II. This classification requires the Supplier to use sources certified by the Purchaser.
Certified: The initial and periodic qualifications of Suppliers who have been subjected to an on-site evaluation of Special Process facilities, procedures, personnel and controls and have satisfactorily demonstrated their ability to meet the applicable specification requirements.
Certifying Agent: A group of Aviation special process experts with authority to approve technical plans & repair procedures.
Change in Design (CID): A controlled document issued by AVIATION to change an engineering drawing or specification.
Delegation Authority: As appropriate, establishment and approval authority of Engineering or Quality requirements, may be delegated through documentation by the function where that authority is vested.
Development Qualification Tests: Component, system and engine tests performed to demonstrate the suitability of a component for flight-testing and production.
Design Intent: The responsible engineer's conception of the intended use of an item and its ability to meet all performance and life requirements in its operational environment; the engineering definition of which is communicated via an engineering drawing or specification.
Electronic Vendor Substantiation Engineering (eVSE): AVIATION Internet based system that manages the Source Substantiation process and represents the electronic version of the SSP form.
Engineering Function: The function (i.e. Design, Materials Applications, Standards, Systems, etc.) responsible for establishing engineering requirements, reviewing and approving the Source Substantiation Plan and associated data package.
Engineering Source Substantiation Requirements: The engineering requirements over and above the requirements as defined by the Engineering drawing and applicable specifications.
Farmout: The purchase of operations/services required for the manufacture of a component for Aviation hardware designated as internal-make (ref. 879.02).
Hardware Process Review (HPR): A review of a Supplier's product and/or manufacturing process by a team that may include AVIATION auditor(s), AVIATION Quality Representative(s), and process specialist(s) to evaluate adequacy and compliance with AVIATION requirements.
Nadcap: A consortium of prime aerospace Original Equipment Manufacturers that control and accept special audits performed by a third party. Note: currently, Performance Review Institute administers this program.
Post VSE Review (PVR) – A review, 6-24 months after initial VSE approval, to validate a VSE component manufacturing and quality planning and the introduction of process and design changes.
Priority Part: A high energy rotating part, a high-pressure casing, or a single-element mount structure in an approved Aviation engine design, that if it were to fail, could have a major impact on the airworthiness of aircraft in service from the viewpoint of potential non-containment, engine structural problems, or mount integrity events.
Purchaser: The procuring activity of AVIATION that issued the procurement document invoking this document. When this document is invoked by a U.S. Government purchasing activity (or such activity's designee), the Purchaser shall mean such activity or designee as the case may be.
Purchase Order/Agreement – (PO/PA): The formal legal contract between AVIATION and the Supplier covering the purchase of materials and services.
Raw Material: Metallic or non-metallic material in its basic form (i.e., sheet, bar, wire, powder, resins, fibers, adhesives, plastics, elastomers, honeycomb, etc.), including castings and forgings used to manufacture AVIATION products, and which remains present in whole, or in part, in the finished product.
Revenue Share Participant (RSP): AVIATION selected sources that have an agreement with AVIATION for the purpose of sharing both the development costs of the new engines and the revenue derived from the sale of those engines. AVIATION maintains overall design responsibility for customer end use product, but may delegate detail part design to the RSP.
Rework: 1) A procedure applied to a nonconformance that will completely eliminate it and result in a characteristic that conforms completely to engineering requirements (i.e., drawings, specifications, etc.). 2) Processing to convert a part or assembly from one P(art) or G(roup) number to another or from one drawing number to another. These changes can be the result of a manufacturing decision or may be required by an approved change document (CID, DCID, etc.) or rework drawing (Shop Mod, etc.). The organization doing the rework need not be the original manufacturer but the resulting part's history must be carefully documented.
Significant Process: A process or process sequence, that if changed could affect design intent; material structure, mechanical, chemical or electrical properties; and cannot normally be evaluated without destructive testing.
Significant Process Change: A change to a process previously identified as significant, a change from a non-significant process to a potentially significant process, addition of a significant operation, or a change in the location (i.e. equipment or facility) at which a significant process is performed on any component. Temporary changes are included.
Significant Sequence Change: A change in the sequence involving a significant process and/or any change in the sequence of Non-Destructive Evaluation, or testing with relation to the significant process.
Source Substantiation (SS): The engineering requirement to verify that a component manufactured to a specific process and drawing requirement meets the design intent and that parts produced by an alternate source/process must be equivalent to the part originally qualified. The parts produced by the alternate source/process need not be equal in all respects, but must fully satisfy all physical and functional engineering requirements, as defined by the source substantiation requirements, engineering drawing and applicable specifications.
Source Substantiation Listing (SSL): A list used for Supplier Designed Components that provides significant processes, procedures, substantiation testing, and the approved Source for each significant process identified (ref. P1TF17).
Special Processes: Those processes which modify or change the inherent physical, chemical, electrical or metallurgical properties of an item, or non-conventional methods which remove or deposit material on an item during or after fabrication which cannot be fully evaluated by non- destructive means, or those used to maintain process control such as nondestructive testing. Typical processes are listed in the AVIATION "Yellow Pages".
Supplier: Sources (including distributors, warehouses, processors, and revenue share participants) other than AVIATION, that supply material, parts, processes, or services for incorporation into AVIATION products. May also be referred to as “Source”.
U.S. Army Flight Safety Part (AFSP): Any part, assembly, or installation whose failure, malfunction, or absence could cause an uncommanded engine shutdown, and/or a catastrophic engine failure resulting in loss or serious damage to an aircraft and/or serious injury or death to the occupants. For dual engine applications, this definition is limited to include components or parts whose failure could result in uncontained components, or could cause an external fire in the engine bay, or any component that has less than certain in-flight shutdown rates as defined by the customer.
Vendor Substantiation Engineering (VSE): See the definition provided for SOURCE SUBSTANTIATION
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Issue Date: 10/30/2009 Printed Copies Will Not Be Kept Up To Date
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