Quality Assurance
Quality Assurance
The Quality area is responsible, among other things, for everything related to the company's risk management through the Business Continuity Plan.
During 2023, work was carried out on risk management at all levels of the organization, from business continuity, with the applicability of PSC-1003 (based on ISO 22301:2019), to operational and project risks covered in PSC-61 and SE8503. The risks applicable to the product/process are specifically listed by operation in the PFMEAs for each product according to PSC-35.
Business Continuity Plan (BCP) is a documented method including instructions for the company to respond in the event of a disruption, to recover its deliveries to the customer in the shortest possible time.
Along with the BCP definition, it is decided what the objective of the deployment project is, where it is deployed, the method to be used and who participates per area:
- Which (Continuity Plan Objective): Keep delivering to the customer when a disruption arises.
- Where (critical areas to be considered): It must be deployed throughout the company by plant, considering facilities, industrial means, supply chain and IT.
- How (method): A pilot project was launched in Composite's plants, which, once completed and with the lessons learned, would be rolled out to the rest of the organization.
- Who: The management MFT is divided into the different MFTs involved in each plant. These MFTs consist of the first level of the organization.
The BCP process starts with the definition of critical areas in the organization (to support the delivery of products and services), and then defines which key areas/programs should be included in the BCP analysis. More specifically, an analysis is made of all the systems, machines, equipment and people involved in the BCP to assess the risks and establish an action plan to achieve the objective (RTO, recovery time, less than MTPD, maximum acceptable downtime). Finally, with all the information gathered, the Business Continuity Plan is described for each technology. In 2023, deployment to Assembly and Aeroengines has been completed.
Due to the Aciturri-Alestis integration process, the procedures were reviewed in the last quarter of the year to extend their applicability to the entire scope. Specifically, Business Continuity is scheduled to be extended to all Alestis plants, including the facility in Brazil, in 2024, as well as the rest of the Quality management system procedures.
Meanwhile, at the Rochefort plant, the company's own procedures (DG01-03 A) were kept in place for 2023; although the BIA (Business Impact Analysis) was completed, the continuity solutions were implemented, and the actions to be taken were established. Documentary integration is scheduled to be completed during 2024.
"The team has scaled up production of the LEAP Hub to support the customer with 100% of this component on the LEAP 1A."
The company is certified under ISO 9001 and EN9100 for all plants, in addition to being a POA organization according to EASA21G at the Aerostructures plants (except for the Getafe plant); EN9110 for the assembly plants; ISO 17025 for calibrations at the Tres Cantos plant; PECAL 2110/ PECAL 2310 for Tres Cantos (manufacturing and design/development), Ayuelas and Orón; EN9120 at the Boecillo plant and Berantevilla Logística; and the NADCAP certifications required, depending on the technology and processes carried out at each plant, for aerostructures, there are NADCAP certified processes at most plants (Boecillo, Tres Cantos, Ayuelas, Vitoria, Seville, Puerto Real, Tecnobahía, Alestis do Brasil), as well as at the Aeroengines plants (Ircio, Orón and Rochefort).
For Alestis' part, 2023 marked the Calidus assembly plant certification process and the integration into the Dassault project's POA.
These certifications represent strict compliance with the applicable regulations and laws and the traceability of every product; all materials used and people involved in their manufacturing and assembly are recorded, and the certifications of the processes that back them up. Their use and maintainability depend on design revisions, first article inspections (FAIs), and official certification tests. According to the Context Matrix, these are crucial issues for clients, civil and military aviation authorities, subcontractors, service companies operating in our facilities, and employees. Proper management allows us to ensure quick response times, adaptability to clients’ needs and any possible legal changes and monitor subcontractors.
Aciturri Aeronáutica was granted the necessary authorizations in 2023 to work on projects requiring handling classified information. In Brazil, the planning of all works to upgrade ultrasound equipment and prepare infrastructures for SAP integration during 2024 was included in 2023.
On the other hand, in Rochefort, the SAE delegation was obtained to evaluate the specific deviation in the thermal and dimensional treatment for LEAP.
Customer complaints are received through Discrepancy Reports (DRs), which are analyzed by Quality departments at the different plants. International formats and tools are used for this analysis, according to EN9136, 8d and 9s analyses are performed according to the company's own procedure PSC-06 (procedure DG13-00AF, in the case of Rochefort) and customers' formats and procedures. These analyses are focused on obtaining the root cause of the problems generating the rejects and determining the actions, both to contain the problem and to correct and prevent it from recurring.
Quality First project remains one of the most important initiatives in the area. This initiative has achieved a 38% reduction in the number of parts affected by DR, including parts from the supply chain.
In 2023, the RFT (Right First Time) initiative was deployed in all Aciturri plants, and it was deployed to the Rochefort plant at the end of the year. The initiative managed to analyze all defects, both HNCs (non-conformities) and reprocesses, and established action plans. In all Alestis plants (including Brazil), monthly monitoring of all indicators of CNQ (Non-Quality Costs), DRs, etc., is performed, following deviations against objectives.
The Quality First project remains one of the most important initiatives in the area. This initiative has managed to reduce the number of pieces affected by DR by 38%, including those from the supply chain.
Regarding the Aeroengines business and the Rochefort plant, due to the applicability in the engine business of the AS13100 (standard derived from the EN9100), the analysis and gaps to be covered for customers SAFRAN and ITP Aero are carried out. Moreover, the QFT (Quality for Trust) concept implemented with Safran Aircraft Engines is developed to implement the ISD for LPT LEAP blades.
[416-1] Every product launched into the market by Aciturri is monitored and evaluated to ensure its compliance with contractual requirements, the standards behind the applicable certifications and current regulations, as well as its safety.
[416-2] In 2023, there were no cases of non-compliance with regulations or voluntary codes associated with the impact of products and services on health and safety.
[417-1] Regarding product labeling, Aciturri is not obligated to include details of the components or instructions for safe handling, as this information for handling and integration is provided in the drawings.
The conformity certificate issued and signed by Aciturri indicates the sales part number, including identification data to track the components and people involved in its manufacture. This certificate ensures that the parts are newly manufactured, and some of them are audited by AESA (Spanish Aviation Safety Agency) to assess this certificate issuance.
In 2023, we continued with the established dynamics, according to which the MDF substances contained in each of the parts numbers manufactured/shipped are periodically transmitted to the main customers.
This year, the deployment of this work methodology started in the plants from Alestis and Rochefort, to be completed by 2024. Identifying and packaging the components is key to avoiding fraudulent or counterfeit materials in the manufacturing process and ensuring optimal delivery conditions, which is why this point is included in the new PSC-35 industrialization procedure.
The Quality Assurance team continued working with aeronautical industry stakeholders, especially with the Spanish Association for Quality (AEC), of which Aciturri is a management member of the Aerospace Committee.
Quality area prepares the data for the Official Catalog on the Spanish Defense Industry every year. The catalog publishes the primary data of companies involved in the defense business and aims to promote the capabilities of the Spanish defense industry in foreign markets.