Mark Hammar
September 18, 2017
Within the requirements of AS9100 Rev D, there is a necessity to not only identify the sequence and interactions of the processes of your aerospace Quality Management System (QMS), but also to maintain this as documented information. While this requirement to understand your QMS processes and their interaction has been part of the AS9100 standard for a while, not everyone appreciates the importance of understanding the interaction between processes. It is in these interactions that savings and efficiencies can be found.
In the world of AS9100 Rev D, a process is any activity that takes inputs and turns them into outputs within your QMS. As the QMS is your collection of processes that exist to allow you to produce and deliver your products and services to meet your customers’ needs, these processes include everything needed to perform these tasks: order taking, procurement, design, production, delivery services, billing, and so on.
So, in short, a process looks like Input –> Process Activities –> Output. You need to understand these processes in order to control them adequately in your QMS, and most people understand this, but they fail to see what lies in the process linkages that can lead to problems:
It is more than just a line on a chart that links one process to another. When you start to lay out all of the processes that you have, you quickly find that the outputs from one process become the inputs to another process. It is these linkages that people often overlook in process control and improvement. As there are two aspects to the linkage of a problem, it is best to look at each separately.
As has been indicated above, not understanding your process linkages can lead to inefficiencies that can become costly and, as such, these interactions are a good place to find easy-to-fix continual improvement activities. However, when the process linkages are not aligned, so that mistakes could occur that lead to errors, then this is a risk that could affect the delivery of your products and services to customers.
For more on operational risk management in the QMS, see this article on 5 key elements of risk management in AS9100 Rev D.
One of the quality management principles behind the AS9100 QMS is the need for continual improvement, and improving your QMS processes is an important part of this activity. However, when you make changes to improve your processes, it is important to keep in mind how this will change your inputs and outputs. If your process improvement will end up eliminating the need for one of your inputs, make sure that the process that previously delivered this input stops creating it. This is often the source of the problem when a process creates an output that is never used.
Likewise, if your process improvement will end up changing your output, such as eliminating some information that was previously available, then make sure that this will not affect the ability of the next process to function. Remember – if a process change is easy for you, but creates more work in other processes than it saves in your process, then it is not really an improvement in the overall system.
Understand your process linkages, and you can make your overall processes more efficient by improving the effect that one process has on the next process. By improving the process linkages, and ensuring that process linkages are maintained during process improvement, your QMS as a whole will be improved – which can lead to greater efficiency and cost savings. And, by knowing how the processes interact, you can also prevent situations where the improvement of one process negatively affects the processes that receive its inputs. Improvement of the overall QMS process is the main reason for having a Quality Management System, so understand your process linkages to increase the quality that your QMS process creates.
For a better understanding of process requirements, read this free white paper: Clause-by-clause explanation of AS9100 Rev D.