1、AEROSPACE AS7115 STANDARD SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of thisreport is entirely voluntary, and its applicability for any particular use, including any patent infringement arisin
2、g therefrom, is the sole responsibility of the user.“SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments andsuggestions.Copyright 2001 Society of Automotive Engineers, Inc.All rights reserved. Printe
3、d in U.S.A.TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS: http:/www.sae.org400 Commonwealth Drive, Warrendale, PA 15096-0001Issued 2001-10NATIONAL AEROSPACE AND DEFENSE CONTRACTORSACCREDITATION PROGRAMREQUIREMENTS FOR ELASTOMER SEALS1. SCOPE:This Aerospace Standard (A
4、S) establishes the requirements for manufacture of Elastomer Seals tobe accredited by the National Aerospace and Defense Contractors Accreditation Program(NADCAP). NADCAP accreditation is granted in accordance with SAE AS7003 after demonstrationof compliance with the requirements herein. The require
5、ments may be supplemented by additionalrequirements specified by the NADCAP Elastomer Seals Task Group. Using the corresponding AuditCriteria (PRI Acs) will ensure that accredited Elastomer Seals suppliers meet all of the requirementsin this standard and all applicable supplementary standards.The pu
6、rpose of this audit program is to assess a suppliers ability to consistently provide a product orservice that conforms to the technical specifications and customer requirements. The correspondingaudit criteria are also structured to obtain information relevant to management practices andprocesses th
7、at directly or indirectly affect the product or service. This information will be used in thedetermination of accreditation status and may be used by the supplier to guide improvements in theproduct or service and the associated processes.2. REFERENCES:2.1 SAE Publications:Available from SAE, 400 Co
8、mmonwealth Drive, Warrendale, PA 15086-0001.AS7001 National Aerospace and Defense Contractors Accreditation Program (NADCAP)Program DescriptionCopyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115
9、-2-2.1 (Continued):AS7002 National Aerospace and Defense Contractors Accreditation Program (NADCAP) -Rules for ImplementationAS7003 National Aerospace and Defense Contractors Accreditation Program (NADCAP) Program OperationAS9000 Aerospace Basic Quality System StandardAS9100 Quality Systems - Aerosp
10、ace - Model for Quality Assurance in Design, Development,Production, Installation and Servicing2.2 PRI Documents:Available from Performance Review Institute, 161 Thornhill Road, Warrendale, PA 15086-7527.AC7115 National Aerospace and Defense Contractors Accreditation Program (NADCAP) -Audit Criteria
11、 for the Manufacture of Elastomer Seals2.3 ISO Publications:Available from ANSI, 11 West 42ndStreet, New York, New York 10036.ISO 9001 Quality systems - Model for quality assurance in design/development, production,installation and servicingISO 9002 Quality systems - Model for quality assurance prod
12、uction, installation andservicing2.4 AIAG Publications:Available from AIAG, 26200 Lahser Road, Suite 200 - Southfield, MI 48034.QS-90002.5 Definitions:AOQL: Average Outgoing Quality LimitAQL: Average Quality LimitBATCH: The quantity of compound run through a mill or mixer at one time.CpK: Capability
13、 Index for a Stable ProcessGQS: General Quality SystemLOT: All the product from the same batch of compound processed in one continuous run andpresented for manufacturers inspection at one time.LTPD: Lot Tolerance Percent DefectiveCopyright SAE International Provided by IHS under license with SAENot
14、for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-3-2.5 (Continued):MSDS: Material Safety Data SheetPROCEDURE: A written document under document control that defines the specific steps,processes, or services to be performed. The purpose of a procedure is to assu
15、re reproducibility ofresults. Procedures may reference supporting documentation in meeting this objective.SPC: Statistical Process Control3. QUALITY SYSTEM:The manufacturers quality system shall be approved to:SAE AS9000.4. QUALIFICATION OF PERSONNEL:Operators and inspectors shall be qualified by at
16、 least one of the following:a. Training by personnel with documented training proceduresb. Initial technical examinationc. Periodic technical examinationd. Periodic overcheck of work5. WORK INSTRUCTIONS:Work instructions shall be adequate to control the manufacturing process for the following:a. Fun
17、ction to be performed b. Sequence of operationsc. Inspection pointsd. Accept/Reject criteriae. Tools, gauges, and inspection equipmentf. Drawing number and revision levelg. Workmanship criteriah. Inspection methodsi. Tolerance limitsj. Sampling plansk. Special drawing notesl. Part identification6. S
18、TATISTICAL PROCESS CONTROL:6.1 The supplier shall comply with Appendix A for statistical process control methods.6.2 Key personnel and specific SPC functions shall be identified.Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted wi
19、thout license from IHS-,-SAE AS7115-4-6.3 Personnel shall be formally trained in the procedures and techniques necessary to implement SPC.6.4 Records of SPC training shall be maintained.6.5 For all processes or specifications, “Key“ Process and Product Characteristics shall be identifiedand controll
20、ed (includes molds, presses, mold conditions, post cure ovens, etc.).6.6 A list detailing the manufacturing processes or product features and the method of control shall beverified.6.7 The selection of product/process characteristics to be controlled via SPC methods shall beappropriate.6.8 All inspe
21、ction/SPC reports shall be maintained and retained in accordance with procedure andcontractual requirements.7. ACCEPTANCE SAMPLING:7.1 Sampling plans used for inspection shall be defined by procurement/contractual requirements orthey shall be in accordance with the manufacturers procedure.7.2 A desc
22、ription of the sampling plan (or a copy of the plan) shall be available (including a descriptionof part selection method - random, stratified, arbitrary, fixed interval, etc.). Information shall includerequired AQL, AOQL, LTPD, lot size or frequency, sample size, acceptance number, switchingcriteria
23、, referenced statistical standard, etc.7.3 Lot Formation:7.3.1 Size of lots shall be appropriate.7.3.2 Lots shall be homogeneous.7.3.3 Part selection shall be free of bias.7.3.4 Sample size/frequency shall be sufficient to meet the purchasers stated requirements (AQL,AOQL, or other measure of accept
24、able product quality).8. QUALIFICATION/PERIODIC CONTROL:8.1 Product qualifications shall be conducted in accordance with customer specification requirements.8.2 There shall be evidence of periodic control where required.9. FROZEN PROCESSES AND/OR PROPRIETARY MATERIALS AND PROCESSES:9.1 Frozen and/or
25、 proprietary materials and processes shall be properly identified.Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-5-10. REPRODUCIBILITY & REPEATABILITY:10.1 Gauge studies to a nationally rec
26、ognized method shall be performed on all gauging to determinepercent of uncertainty of the gauge.11. PACKAGING:11.1 Packaging and part identification requirements shall be defined.11.2 Packaging requirements shall be specific.11.3 There shall be procedures in place to assure that packaging is in acc
27、ordance with customerrequirements.11.4 There shall be evidence that procedures are followed.11.5 Requirements for packaging shall include instruction on:a. Specification of packaging type (i.e., plastic, cardboard, kraft paper bags, etc.)b. Sealing techniques to assure isolation of the part from the
28、 environment.12. CONTROL OF NONCONFORMING PRODUCT12.1 Material that has been dispositioned as scrap shall be permanently identified as such anddisposed of in a manner that will preclude inadvertent use or shipment.13. ELASTOMER SEALS13.1 General13.1.1 There shall be a properly identified and referen
29、ced procedure to manufacture.13.1.2 Equipment shall be defined.13.1.3 Equipment shall be on a suitable maintenance schedule.13.1.4 Instrumentation shall be defined.13.1.5 Instrumentation shall be on verifiable calibration schedule.13.1.6 MSDS shall be on file.13.2 Raw Material:13.2.1 There shall be
30、a properly identified and referenced procurement specification established for allraw materials used in manufacturing the elastomer seals. This document shall define lotidentification and control, handling precautions, and storage requirements.Copyright SAE International Provided by IHS under licens
31、e with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-6-13.2.2 Requirements shall be established for the following incoming checks:a. Labeling and identificationb. Certification of analysisc. Verification of material13.3 Compounding and Mixing:13.3.1 T
32、here shall be a written procedure for compounding, mixing, and storing mixed products.13.3.2 There shall be guidelines for storage and handling of raw materials prior to mixing.13.3.3 As applicable, age limits established for raw materials and compounds and appropriate recordsshall be maintained.13.
33、3.4 There shall be provisions included in the calibration procedure to assure the accuracy ofweighing equipment.13.3.5 Mixing procedures shall be specific and monitored.13.3.6 There shall be procedures to verify that the correct compound ingredients in the correctquantities have been mixed prior to
34、molding.13.4 Molding of Elastomer Seal13.4.1 There shall be a written procedure for correct preform preparation.13.4.2 There shall be a written procedure for molding that provides for the following:a. Proper cleaning, storage, and inspection of toolsb. Identification of specific press equipmentc. Ve
35、rification of molding conditions that includes: time, temperature, and pressured. Elastomer seal lot identification back to compound batch numbere. If required, verification of correct post curef. Evidence that applicable dimensional checks are performed after molding, post cure, anddeflashingg. Evi
36、dence of physical property verificationh. Proper storage and controls to prevent mixing of seals after molding13.4.3 There shall be adequate controls for monitoring process parameters.13.4.4 Process controls shall be calibrated.Copyright SAE International Provided by IHS under license with SAENot fo
37、r ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-7-13.5 Acceptance:13.5.1 There shall be verifiable evidence that the elastomer seal is controlled for:a. Visual requirementsb. Dimensional requirementsc. Physical property requirements14. COMPLIANCE14.1 Job Audits:
38、Compliance to the requirements contained herein and customer requirements shall be verified byauditing in-process or completed jobs. The number of jobs to be audited shall be determined bythe NADCAP Elastomer Seals Task Group. A minimum of one complete job shall be reviewed forcompliance to all cust
39、omer requirements and the requirements contained herein. If multiple jobaudits are performed, selections of jobs should be based on representative sampling of type ofwork, products, and customers.14.2 Product Verification:A minimum of one complete Product Verification shall be performed. The part sh
40、all be inspectedfor conformance to specifications and customer requirements. Inspection shall take place at thepoint in the process where the characteristic or feature is created.PREPARED UNDER THE JURISDICTION OFSAE COMMITTEE ?Copyright SAE International Provided by IHS under license with SAENot fo
41、r ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-8-APPENDIX AREQUIREMENTS FOR STATISTICAL PROCESS CONTROLA.1 SPC PLANS:A.1.1 The supplier shall have a written statistical process control procedure which details theimplementation of SPC on the shop floor, covering
42、 their products and processes.A.1.2 The supplier procedure for SPC shall describe functions/titles and responsibilities of thosepersons responsible for SPC system tasks.A.1.3 The suppliers SPC procedure shall describe methods and techniques that used to monitor partsand processes to reduce variation
43、.A.1.4 The suppliers SPC procedure shall provide examples of forms, charts, reports, etc. to be used aspart of the SPC program.A.1.5 The supplier procedure shall provide specifically for the following items on key characteristics tobe studied:a. Acceptable accuracy of the measuring systemb. Acceptab
44、le repeatability and reproducibility of the measuring systemc. Evaluation of the process to determine if it is within statistical controls or can be brought intocontrol by removing special causesd. Evaluation of process capabilitye. Evaluation of the need to shift the process mean or determination o
45、f the source and cause ofvariation which prevents an acceptable process capability from being achievedf. Continuous reduction of common causes of variation and measuring improvement byprioritizing action items, developing and implementing action plans, taking and evaluating newdata and seeking new o
46、pportunities for improvementA.1.6 The suppliers SPC system shall provide for the identification of key control characteristics (what,where, when, and how they will be measured).A.1.7 The SPC system shall provide for the immediate notation of signals indicating special causes (bysomeone who works in
47、the process).A.2 MANAGEMENT COMMITMENT:A.2.1 Top location managers shall be conversant with the principles and methods of SPC.A.2.2 Employees and managers shall be knowledgeable of “process capability“ and what is involved intreating common cause variation.A.2.3 Management shall be aware of the leve
48、l of personnel involvement and the SPC implementationphase on the shop floor.A.2.4 SPC charts shall be used in formal management reports.Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-SAE AS7115-9-A.2
49、.5 Discussion with employees shall evidence managements commitment to process control.A.2.6 There shall be examples of improvements in processes based on low Cpk values wheremanagement involvement is apparent.A.3 IMPLEMENTATION PLAN:A.3.1 Operators shall be provided with simple guides for SPC implementation on the shop floor.A.3.2 There shall be a system in place for statistical in-process monitoring of all other productcharacteri
