PS901500E IDENTIFICATION, MARKING, HANDLING, PROCESSING AND INSPECTION OF CRITICAL PARTS

Transcription

1 SECURITY CLASS: UNCLASSIFIED COML. CLASS: UNCLASSIFIED DOCUMENT IDENTIFIER SUBJECT: IDENTIFICATION, MARKING, HANDLING, PROCESSING AND INSPECTION OF CRITICAL PARTS MATERIAL ENGINEERING & TECHNOLOGY DEVELOPMENT ENGINEERING DIVISION / COMMERCIAL AIRCRAFT GROUP DATE: 31/7/06 This document contains proprietary information of Israel Aircraft Industries Ltd., and may not be reproduced, copied, disclosed or utilized in any way, in whole or in part, without the prior written consent of Israel Aircraft Industries Ltd. PS doc PAGE: 0.1 REVISION: E2

2 SECURITY CLASS: UNCLASSIFIED COML. CLASS: UNCLASSIFIED DOCUMENT NO. REVISION STATUS REV -- A B C D D1 E E1 E2 DATE 9/84 8/87 11/92 7/95 12/98 1/00 6/00 9/00 7/06 PAGE PAGE PAGE PAGE NO. REV SIZE NO. REV SIZE NO. REV SIZE NO. REV SIZE 0.1 E2 A E2 1 E2 2 E 3 E 4 E1 5 E 6 E 7 E A40 ADDED PAGE ADDED PAGE ADDED PAGE ADDED PAGE NO. REV SIZE NO. REV SIZE NO. REV SIZE NO. REV SIZE PAGE: 0.2 REVISION: E2

3 1. APPLICABILITY Applicable to all projects. 2. SCOPE 2.1. This Process Specification (PS) establishes requirements and procedures for the identification, marking, handling, processing and inspection of Critical Parts or areas of Critical Parts as identified on IAI Engineering drawings Definitions Critical Part: aircraft part wherein a defect may result in fatigue or fracture failure and could either endanger the crew or cause the loss of the aircraft. Note: Structural Significant Items (SSI) are not defined as critical parts and need not be treated as such per requirements of this PS IAI Quality Assurance (IAI QA): the IAI Quality Assurance organization which has been assigned overall responsibility for the end product, on which the critical part is used Quality Assurance (QA): any quality assurance organization which has been authorized, by IAI QA, to verify the implementation of the requirements for critical parts, as given in this PS. 3. APPLICABLE DOCUMENTS 3.1. IAI Ltd. 2 Except where a specific issue is indicated, the current issue of the following specifications shall be considered an integral part of this PS. PS PS PS PS PS PS Application of Epoxy Paint System Application of Fluid Resistant Epoxy Paint System Application of Polyurethane Camouflage Paint System on Aircraft Exterior Polyurethane Corrosion Preventive Coating for Aircraft Integral Fuel Tanks Identification (Name) Plates NDT Personnel Qualification and Certification PS Traceability Procedure for Critical Parts - Engineering Requirements 3.2. U.S. Military MIL-P Primer Coatings; Epoxy High - Solids 3.3. U.S. Federal FED-STD-595 Colors Used in Government Procurement. 31 July 2006 P R O C E S S S P E C I F I C A T I O N Page 1 of 7

4 4. ENGINEERING DRAWING CALL-OUT The applicable Engineering document (drawing, E.O., route card, repair tag etc.) shall reference this PS by number as detailed in para TABLE OF CONTENTS Para. Title Page 1. APPLICABILITY 1 2. SCOPE 1 3. APPLICABLE DOCUMENTS 1 4. ENGINEERING DRAWING CALL-OUT 2 5. TABLE OF CONTENTS 2 6. MATERIALS 2 7. EQUIPMENT AND TOOLS 2 8. REQUIREMENTS Call-Out Procedures Marking of Critical Parts Handling Traceability Manufacturing Route Card 5 9. PROCEDURES Inspection Procedure Material Review QUALITY ASSURANCE Responsibility for Inspection Inspection ENVIRONMENTAL REQUIREMENTS 7 6. MATERIALS Not applicable. 7. EQUIPMENT AND TOOLS Not applicable. Page 2 of 7 P R O C E S S S P E C I F I C A T I O N 30 June 2000

5 8. REQUIREMENTS 8.1. Call-Out Procedures Call-Out on Engineering Drawings Item Identification Critical parts shall be identified on their defining drawings by means of a flag note linked to the part and recorded in the drawing parts list. a. The flag note to be used must be the unchanged standard note MA03 which reads as follows: MA03: CRITICAL PART - PROCESSING, HANDLING AND INSPECTION PER IAI PS b. Add note specifying NDT requirements. c. When applicable, add note specifying special raw material testing requirements (fracture toughness, etc.). d. The initial release and all changes to drawings defining Structural Critical Parts must be approved by the responsible Stress Department Particular characteristics of metallic critical parts, e.g., dimensions, areas, and surface finish of complete parts, shall be flagged on the drawing with the symbol <C>. Note: Characteristics of composite parts should not be flagged Critical metallic parts shall be color identified by special paint (refer to para ). Areas which must not be painted shall be noted on the drawing. These areas include external surfaces and areas where painting may interfere with the functioning of the parts Assembly Drawings When a critical part (per para ) is called out in the parts list of an assembly drawing it shall be identified by an appropriate flag note (refer to para a) linked to the part record in the assembly drawing parts list Call-Out on Manufacturing Documents and Tags Documents and tags relevant to critical parts shall be prominently identified by the following notation: <C> CRITICAL PART HANDLE WITH CARE Documents and tags shall also include Part Number (PN) and Serial Number (SN) as outlined in PS Documents and tags shall assure traceability, by inclusion or reference, to manufacturing records (e.g. route cards), quality assurance records, MRB records, certification, test reports, NDT reports and any other documentation related to the fabrication, processing, inspection, handling or assembly of a critical part. 30 June 2000 P R O C E S S S P E C I F I C A T I O N Page 3 of 7

6 8.2. Marking of Critical Parts Raw Material Page 4 of 7 The IAI batch number of the raw stock, intended for the manufacture of critical parts, shall be recorded on the route card to maintain raw material traceability per PS Parts in Fabrication Each critical part shall be marked with an SN designation per PS , para Parts for Assembly All critical parts, regardless of what method is used to identify them as critical parts, shall be traceable after assembly by part serial number (SN) in the aircraft serial parts list Metallic Parts All critical metallic parts shall be identified by name-plates as specified in para Whenever the geometry, size, or location of the part does not permit the use of a name-plate the critical part shall be identified as follows: a. Critical parts not exposed to fuel or hydraulic fluid shall be painted with a darkgreen (color per FED-STD-595) topcoat per PS b. Critical parts requiring resistance to hydraulic fluid (e.g. Skydrol) shall be painted with fluid resistant epoxy primer per PS and a dark-green (color per FED-STD-595) polyurethance top coat per PS c. Critical parts located in areas exposed to fuel shall be painted with a green polyurethane fuel resistant coating coating (Courtaulds Aerospace Coating 825x309/ ) per PS Color identifications shall be applied only on areas which do not affect the function of the part (i.e., delete in areas of sliding, tight fit, etc.) For external parts that require special coloring, the required color may be painted over the identification primer on external visible areas only Parts which cannot be identified by a dark green color, and tagging is impracticable, shall be packaged in a plastic bag with an attached tag until assembly Composite Materials Parts Parts of composite materials shall be identified by name-plates per para Optionally riveting may be used as the method of their attachment when specified on the Engineering drawing Name-Plates Name-plates shall conform to PS (paint systems not applicable) The location of the name-plates shall be specified on the Engineering drawing Bond name-plate to part per PS , Class II, Type F adhesive Name-plate shall include the PN and SN, refer to para , of the primary detail part. P R O C E S S S P E C I F I C A T I O N 1 15 Sept. 2000

7 8.3. Handling Extra care must be taken so that noted critical parts or areas are kept free of nicks, gouges, scratches, etc Traceability Critical parts shall be processed as necessary to maintain complete traceability, as specified in PS Manufacturing Route Card Fabricators of critical parts shall be responsible for preparing the manufacturing route card related to the fabrication of the critical part. A copy of the route card shall be submitted to IAI QA prior to processing, for review and concurrence The route card shall contain sequential fabrication, handling, processing, testing, inspection and marking steps in the correct order as required. All specifications and applicable classes shall be listed on the route card in the proper sequence. The route card shall include identification of fabricators who are to accomplish any of the processing steps Changes or revisions to an approved manufacturing route card, which alter the processing sequence or change fabricators, shall be resubmitted for review and concurrence by IAI QA prior to implementation of the change. Each revised, approved route card shall be assigned a revision letter or a revision number The route cards for critical parts shall contain steps for preserving the serial number throughout the production process (i.e. - (1) start of machining, (2) before and after operations that would remove the number, and (3) after completion of processing) Acceptable "first article" examination, required by IAI Quality Assurance (IAI-QA), is mandatory prior to routine manufacturing of critical parts. 9. PROCEDURE 9.1. Inspection Procedure Non-destructive Testing (NDT) Written Procedure Approval a. For metallic raw material, the procurement specification shall cover all necessary NDT requirement. b. For metallic parts, a written NDT procedure is required for critical parts. c. For composites, the NDT procedure is required only for critical parts (not for the raw materials) In both cases the written procedure shall be submitted to IAI QA for Conditional Approval prior to testing. IAI QA shall validate the NDT procedures on-site when those procedures that require validation are part of Conditional Approval. IAI QA retains the option to waive on-site validation requirements, but procedure approval is mandatory. When validation is required, suppliers shall notify the IAI QA prior to first part inspection and the validation by IAI QA of the NDT procedure. All revisions to approved NDT written procedures shall be identified by a revision letter and shall be submitted to IAI QA for approval prior to implementation. 30 June 2000 P R O C E S S S P E C I F I C A T I O N Page 5 of 7

8 Complete NDT written procedures for penetrant inspection need not be submitted for each part. A general penetrant inspection procedure may be approved and supplemented with individual procedures for each part. Note: NDT personnel qualification and certification shall be per PS First Article Inspection After the first article of a critical part is completely manufactured in accordance with the Engineering drawing, IAI QA shall be contacted to perform the First Article Examination Each new supplier of critical parts, or each major change in production equipment or manufacturing practice, shall be the subject of another First Article Examination An Engineering drawing change that requires a new First Article Examination shall note the requirement on the change EO IAI QA shall conduct the examination after receipt of the request Routine Inspection of Critical Characteristics Critical parts and critical assemblies shall be 100% inspected for surface finish to ensure that parts are free of nicks, scratches, sharp edges, sharp inside corners, etc., that are visible to the naked eye Where particular part characteristics are flagged with the symbol <C>, the part shall receive 100% inspection of these characteristics on 100% of the parts unless the manufacturing process is automatic (such as numerically controlled [NC] machining and NC drilling and riveting) or unless the tooling guarantees repeatability of characteristics within tolerance as specified on the Engineering drawing Deviation from the 100% dimensional inspection requirement because of process automation or tooling that guarantees repeatability shall require initial inspection of the tools, tool prove-out after installation and inspection of first piece manufactured and subsequently the periodic inspection of tools and sampling inspection of parts machined. These parts shall still receive a 100% visual inspection per para above. Note: 9.2. Material Review Periodic shall be defined as before beginning production of every batch. Material Review Board (MRB) actions for critical parts shall be approved by the relevant responsible Engineering Department. Page 6 of 7 P R O C E S S S P E C I F I C A T I O N 30 June 2000

9 10. QUALITY ASSURANCE Responsibility for Inspection Inspection IAI QA shall be responsible for ascertaining compliance with the requirements of this Specification. IAI QA shall verify that: a. Documents and tags are properly marked with critical part notation. b. Manufacturing plans and NDT written procedures have been approved, reviewed, and concurred with, in accordance with this PS. c. Operations and inspections are performed in accordance with the approved route card. d. The required documents are referenced on the route card. e. The manufactured part First Article Examination by IAI QA is accomplished prior to acceptance of additional units. f. Complete traceability per PS for critical parts is observed. g. Parts bearing the <C> symbol are 100% inspected. 11. ENVIRONMENTAL REQUIREMENTS Cleaning and painting processes may cause unfavorable impacts on the environment. Refer to the relevant cleaning or painting process specification to minimize these effects. 30 June 2000 P R O C E S S S P E C I F I C A T I O N Page 7 of 7