
Aircraft assembly has changed over the years from purely manual to automated processes. Previously, OEMs assembled the individual parts themselves. Now they sub-contract small bench-top through large complex assembly modules, then OEMs assemble these modules into an aircraft. The Aero Structure Assembly (ASA) Task Group addresses all manufacturers in the supply chain regardless of their tier level when performing any type of aircraft assembly details. Inspection programs are also evolving from inspectors signing off on operations to operators performing self-verification.
The number of companies involved in aero structure assembly has grown over the years, and the work carried out by the aerospace supply chain has become more complex and intricate. The risks associated with such work are various and significant; product defects can have serious consequences. As a result, there is a need for a rigorous oversight program to assure that outsourced work is being completed in accordance with industry standards and customer requirements.
The Nadcap® Aero Structure Assembly (ASA) accreditation program satisfies this need for compliance validation. The Aero Structure Assembly task group was established in 2017. Today ASA has accredited more than 40 suppliers and is increasing yearly. ASA accredited suppliers are more than doubling each year.
INDUSTRY SUPPORT
Participating Stakeholders:
- Airbus*
- Airbus Defense*
- BAE Systems
- Embraer*
- Lockheed Martin
- Northrup Grumman
- Sonaca
- Spirit Aerosystems
(* mandates)
BUSINESS BENEFITS
- Federal Air Worthiness Board requires subcontractor oversight
- Cost reduction associated with product escapes
- Elevate industry reputation
- Going from reactive to preventative change
- Improved on-time delivery due to better control of the supply
chain – harmonization - Mitigate in-service risk of product failure
- Reduced scrap and rework
- Improved product quality
TECHINCAL BENEFITS
Reduction in nonconforming product by ensuring a more in-depth review of customer specifications and requirements, such as:
- Operator qualification and training
- Correct tooling for materials and applications
- Kit review for correct components, undamaged, etc.
- Fixturing/jig review
- Conversion coating touch-up
- Surface prep for conversion coating, adhesion promoter, and sealing application
- Bushing and Bearing installation / retention
- Specific Customer requirement flow down
- Environmental controls for shelf life materials and sealing applications
AUDIT CRITERA
AC7135 - ASA Hole Preparation, Dimpling, Auto and Semi-Auto Assembly
AC7135/1 – Fastening
AC7135/2 – Electrical Bonding
AC7135/3 – Bushing and Bearing Installation
AC7135/4 – Sealing of Aerospace Assemblies and ComponentsCOMMON INDUSTRY ISSUES
- Misinterpretation of and non-compliance to customer requirements
- Incorrect fastener, bushing and bearing installation methods
- Improper surface preparation and cleaning for conversion coating and sealant application
- Missing customer requirements and operations in work instructions
- Omission of customer specification required inspection operations
- Inadequate environment controls for storage and application of temperature-sensitive materials
- Inadequate temporary fastening, clamping, and fixturing prior to assembly
- Poor workmanship of sealant application
- Operator training programs not including review of customer specifications and requirements