At the Praxair Surface Technologies, Inc. aviation services facility in Hillsboro, Ohio, engineers inspect an engine combustion chamber to determine whether it meets original equipment manufacturer (OEM) requirements for continued safe operation. The surface appears solid, but nondestructive testing (NDT) sees where human eyes fail. When engineers apply ultrasonic waves followed by a fluorescent penetrant, microscopic indications may appear. Further testing will determine if these indications are superficial, or may result in unacceptable failure.
Praxair Surface Technologies has established a reputation for quality services, including NDT. They also manufacture precision engine components for prime aerospace customers, produce specialty coatings, and provide heat treatment, brazing and certified welding.
According to Wayne Lowery, Quality Manager of the Hillsboro facility, quality is not a choice – it is standard operating procedure. His company was one of the first registered to AS9100. Aerospace companies must establish a quality management system (QMS) that complies with Federal Aviation Regulations (FARs), as mandated by the Federal Aviation Administration (FAA). While registration to AS9100 is optional, many aerospace OEMs demand it from suppliers.
“Total customer satisfaction is an internal Praxair Surface Technologies commitment, and some of our customers also demand AS9100,” said Lowery. “If we’re AS9100 compliant and certified to Nadcap, our customers don’t waste time and resources auditing us. They know we’ll strive to exceed expectations.” Under Nadcap, suppliers’ special process control systems are evaluated to demanding standards and registered by a third party on behalf of supporting OEM companies.
Before registering to AS9100, the internal QMS must meet approximately 100 requirements beyond those specified in ISO 9001. While adhering to local, state and federal laws, the QMS must also be customer-oriented, provide framework for leadership, promote employee involvement, apply the process approach, seek continual improvement and foster mutually beneficial supplier relationships.
“Aerospace OEMs are subject to a high level of product liability, and therefore demand superior supplier performance,” said Lowery. “Safety, airworthiness, product conformity and reliability are key aspects of AS9100 certification.”
At Praxair Surface Technologies, the QMS applies not only to product quality, but also business performance metrics (manufacturing efficiency, speed to market, cost of quality, cycle time reduction and delivery speed). Proprietary “TAT Tracker” software focuses on improving Praxair’s delivery by monitoring actual turn around time (TAT) and on-time delivery performance.
“Industry suppliers usually discover that AS9100 registration reduces waste, and the improved efficiency immediately appears on the bottom line,” said Lowery.
The aerospace industry is both cyclical and competitive; therefore AS9100 addresses supplier-rating systems. These systems help identify outstanding supplier performance as well as allow for disapproval of suppliers who do not meet customer requirements.
Before AS9100, suppliers regularly underwent multiple audits from OEMs, the Department of Defense (DoD), the National Aeronautics and Space Administration (NASA), the FAA and other interested parties. To streamline quality accountability within the industry, OEM quality leaders formed the American Aerospace Quality Group (AAQG) and helped create AS9100 to reduce variation and redundant audits while maintaining control of companies in the supply chain.
This industry initiative was soon elevated internationally, and the International Aerospace Quality Group (IAQG) was formed “to establish and maintain a dynamic cooperation based upon trust among international aerospace companies, on initiatives to make significant improvement in quality and reductions in cost throughout the value stream.”
Lowery said, “Praxair Surface Technologies chose QMI as its registrar because QMI auditors are critical. After determining that we met minimum requirements, they identified areas which presented potential for improvement.”
Click here to see all Customer Success stories