Digital Product Definition

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Assessor Task Guide

Digital Product Definition/Model Based Definition Checklist

D6-51991 Revision J

REVISED October 12, 2010

Notes

This Assessor Task Guide for the Digital Product Definition/Model Based Definition Checklist is intended to provide guidance

and understanding of the questions of the check list to the Supplier that is undergoing a DPD assessment. It is also intended

to provide the auditor with information for use during the execution of the assessment.

The task guide is split into 4 sections.

¾ Section A of the checklist is used to perform a basic Digital Product Definition (DPD) capability verification.

¾ Section B is used to perform Model Based Definition (MBD) capability verification.

¾ Section C is used for Coordinate Measurement System (CMS) capability verification.

¾ Section D is used to perform Plotter capability verification.

The checklists for Sections B, C & D are designed to build upon the basic DPD capability assessment from Section A,

therefore, Section A must be performed prior to performing assessment for CMS or MBD. The MBD, CMS and Plotting

sections may not be applicable if the supplier does not require these capabilities for tooling or production use.

The person performing the DPD assessment should review contract language for DPD, Tooling and Design requirements prior

to performing assessment (some questions may not be applicable based on contract review). The review should be performed

for all sites sending datasets to the supplier to ensure that all site requirements are identified.

Rapid change of equipment capabilities requires changing quality control practices. Guide questions/examples are not

necessarily applicable to each supplier’s manufacturing process.

Definitions

Authority Dataset

This is the engineering definition provided in a 3D representation of the product, viewable on a Computer Aided Design (CAD) system. In

addition to the Authority dataset (aka CAD model), the entire product definition may typically include additional media such as parts lists, part

coordination documents, material specifications, etc.

The Engineering definition may include:

1) The CAD model and fully dimensioned 2D drawing sheets.

2) The CAD model and simplified or reduced content 2D drawing sheets.

3) The 3D model and the engineering requirements displayed as text within the 3D viewing area of the model, as well as the remaining

engineering requirements (in 2D form - notes list, part lists, etc.).

All three formats are considered Digital Product Definition (DPD). The second case is a reduced content format, and is sometimes labeled as

Reduced Dimension Drawing (RDD) or Simplified Drawing (SD). The third is termed Model Based Definition (MBD).

The purpose of the DPD/MBD checklist is to verify that the supplier has processes to use any of these formats received from any Boeing site,

to manufacture and inspect the product.

PRODUCT ACCEPTANCE SOFTWARE

This is software used during Product Realization that potentially affects product conformity where there is no further, downstream verification

of the product. (E.g., CAD, LEV, CMS, data handling/analysis, and in some cases, NC)

COORDINATE MEASUREMENT SYSTEMS (CMS)

CMS devices check the 3D Features of products. Typical examples are the fixed Coordinate Measurement Machine (CMM), and several

portable devices, Theodolite, Laser Tracker, Photogrammetry (includes Videogrammetry), and Portable CMM.

DATASET DERIVATIVE

The media created any time data is extracted from an Authority dataset for machine programming, visual aids, inspection aides, FAIs, tool

fabrication/measurement, plotting mylars, or what have you. Derivative is data taken from its native environment and used in another CAD

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CAM or CAI software system. The geometry is translated from one system to another using a neutral format translator or manual into some 2

D systems.

ENHANCED REFERENCE SYSTEM (ERS)

This is a documented permanent or temporary reference system used usually for large assembly tools, with a large number of digitally-

defined, fixed target locations readable by coordinate measurement systems. It provides better repeatability than conventional tooling datum

features.

IGES, STEP, DXF, PARASOLID

Standardized formats for CAD data that are readable by multiple systems.

LOW END VIEWER (LEV)

An entry level, visualization CAD system used to view, analyze, extract, and print dimensional and other required data from the DPD dataset.

Currently, the only Boeing approved LEV’s used with our Boeing’s MBD datasets are Enovia DMU and VisView. These systems usually do not

support neutral format output.

Checklist Question What to look for…

A. Digital Product Definition:

1. Are there DPD documented processes or

procedures that address all sections of

D6-51991?

Requirements

D6-51991, Sec 1.1

• Documented processes that control Boeing release authority dataset and other

DPD/MBD derivates (i.e. NC programs, Inspection plans, Tooling, etc.) from the point

when the Boeing authority dataset is received, through derivate creation, performed

programming, manufacturing planning (visual aids, in-process inspection, final

inspection), first article inspection and any other process that is applicable.

• There must be a process to ensure the original authority datasets are secure, backed up

and can not be altered, and only the appropriate people have write access to part

programs and inspection datasets.

• Must have trained system administrator(s) with sole access to retrieve and store

incoming customer datasets.

• A process for the supplier to check dataset integrity upon receipt.

• Segregation of datasets by status — (e.g., release, in-work and obsolete are minimum

requirements)

• Security – (Password and access protection, regular back up for disaster recovery and

archive storage).

• Documented processes that address all sections of the D6-51991.

2. Is there a flow diagram of the complete

documented DPD processes?

Requirements

D6-51991, Sec 1.2

• There must be a flow diagram that documents the complete DPD processes and

identifies the applicable procedure references.

• Flow chart should include reference to affected organizations such as (engineering,

manufacturing planning, tooling, inspection and procurement).

3. Is there a requirement in the suppliers

documented processes to notify

customer within 30 days of any

changes or at a minimum annually if no

changes occur.

Requirements

D6-51991, Sec 1.3

• The supplier must have a process that notifies the customer when changes are

incorporated into their DPD process and impacts the customer (simple typographic

errors need not apply)

• The process should include notification within 30 days of any change along with an

annual notification regardless of changes.

• The future process will require suppliers to update their profile online. This will be

known as the Integrated Supplier Information System (ISIS).

4. Are documented DPD processes

implemented with defined authority for

change control & maintenance?

Requirements

D6-51991, Sec 1.3

• Look for approval or signature page and a document control procedure

• Notification to affected personnel and sub-tier suppliers when changes occur.

• Processes should be under document control

• Definition in the procedure as to who is responsible for this document. (Maintenance

along with ownership

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Checklist Question What to look for…

A. Digital Product Definition:

5. Is there a process to ensure integrity and

security of datasets from receipt

throughout the manufacturing and

acceptance processes?

Requirements

D6-51991, Sec 2.1

• Storage of Boeing provided DPD and supplier created derivatives

• Archiving old revisions

• Encryption during send/receive

• Backup system with including remote storage and disaster recovery

• Access control with permission and/or password protection (read/write) to ensure

Boeing provided datasets will not be inadvertently modified.

6. Does the supplier have a process to

control configuration of dataset derivative

media?

Requirements

D6-51991, Sec 2.2

• The derivatives/media must have a revision level process to keep the derivatives/media

current with authority dataset revisions that affects its configuration. As an example look

for these indicators:

• Creator/Date

• Sketch Revision Level

• Authority Dataset(s) Name, Location, Revision Level

• Other Derivative Dataset(s) Name, Location, Revision Level

• Feature Requirement(s) Identifier (e.g., GDT frame ID)

• Product identification

Note: Derivatives are modified copies or extracted data from the original authority dataset.

NC/CNC type programs and the geometry used to create them, visual aides, Mylars,

digital tool designs and tools, inspection datasets, FAI datasets, etc.

7. Are dataset derivatives traceable back to

the current authority dataset?

Requirements

D6-51991, Sec 2.2.1

• Traceability is looking at whether or not the derivative can be clearly identified and tied

back to its Authority dataset, such as when visual aides or screen-prints are being used,

they need to be traceable back to the current Authority dataset.

• Make sure you can trace all derivative back to the authority data. This may be by

revision letter, number or even date and time stamps for N/C processed data.

• All must include reference to the Digital data nomenclature. Look for some sort of history

of change.

• Make sure that this traceability covers SCDs when suppliers create designs.

8. Does the planning package identify

traceability to the current authority

dataset?

Requirements

D6-51991, Sec 2.2.2

• The supplier needs to have a documented process to ensure the planning is traceable

to the correct authority dataset.

• Planning used for route sheets, travelers, work instructions, NC programs, inspection,

etc. will be traceable to the authority dataset that controls the configuration being built.

Any items used in FAI, Tool buyoff or conformity shall be traceable.

9. Does the supplier have a change control

process for dataset derivative media?

Requirements

D6-51991, Sec 2.2.3

• Verify there is a change control process that updates all derivative dataset elements

when the authority dataset is revised.

• Change control process includes review for:

• Tooling

• NC and CMM program

• Sketches, inspection plans, or 2-D drawings

• FAI documentation / Delta FAI or Tool inspection

• Sub-tier supplier notification

10. Does the supplier have a process that

includes control of non current

(obsolete) authority datasets and

dataset derivatives?

Requirements

D6-51991, Sec 2.2.4

• Segregation and clear identification of current and past revision level datasets in

supplier’s directories.

• Ensure compliance to contract data retention requirements

• Look for separate files that are accessible to production

• Archive process

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Checklist Question What to look for…

A. Digital Product Definition:

11. If providing Type Design or Tool

Design to Boeing, does the supplier

have a documented process for design

and development?

Requirements

D6-51991, Sec 2.3

• The supplier shall describe a documented process for design and development to

ensure compliance to customer requirements. Compliance to Boeing Drafting Standards

and Tool Design standards.

• Designs will have traceability to engineering definition

• Supplier’s released design shall be reviewed for program requirements, the design will

provide the data required to allow the product to be:

• Identified

• Manufactured

• Inspected

• All designs will include the part lists and specifications necessary to define the product

or tool (e.g. material, process, features, annotation, specification, notes, and

manufacturing and assembly data needed to ensure conformity of the product or tool).

• Must include a reference for customer approval when required

12. Does internal quality audits procedure

include auditing or reviewing all internal

and sub-tier operations for DPD data

and related documentation?

Requirements

D6-51991, Sec 4.0

• Internal audit procedures identify DPD processes for review.

• Review audit checklist for compliance. Supplier checklist should address and be

applicable to their processes.

• Review internal audit records for evidence of having a completed internal audit for DPD

processes.

• Internal audit plan shall include provisions for audit of sub-tier supplier oversight

• Review procurement process for flow down and an established ASL for sub tiers

approved to D6-51991 or its equivalent.

13. Does the supplier’s documented

procedure for corrective action include

reporting, tracking and resolving

hardware, software and dataset integrity

(Including Boeing provided datasets)?

Requirements

D6-51991, Sec 5.0

• Processes to report, track, and resolve dataset or software discrepancies to customer,

OEM and all affected personnel.

• Process to prevent use of discrepant datasets or software (remove from system)

• The supplier must have a documented process to disclose products inspected with

discrepant media, equipment, and/or tooling on items shipped to Boeing and their

customers. This would include an internal CA and resolution.

• Existing QMS non-conformance system process.

14. Does the supplier have a process to

assess, monitor and control sub-tier

compliance with DPD requirements?

Requirements

D6-51991 6.1

• Flow down of D6-51991 (or comparable) requirements to sub tiers (PO Note)

• Look for a process for control of the suppliers i.e. what does it take to approve and dis-

approve them?

• Supplier has performed assessment for sub-tiers and ensures the proper capabilities to

manage and use the Boeing DPD/MBD datasets being provided.

• Supplier maintains records of sub-tier DPD capabilities (equipment and process)

• Supplier has documented process to ensure sub-tier supplier’s inspection planning is

compliant when used to accept Boeing product.

• Supplier documented processes ensure sub-tier datasets are verified when translations

occur.

• Supplier performs periodic review on their DPD/MBD sub-tier supplier to ensure they are

in compliance to DPD requirements, Boeing ITAR, EAR and contract requirements.

• Supplier encryption protection for sending/receiving of electronically transmitted data.

Example of supplier purchase order clause. Use Boeing PO clause as example, (includes

ITAR & EAR)

Note; encryption required for electronically transmitted data.

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Checklist Question What to look for…

A. Digital Product Definition:

15. Does supplier QA organization have

responsibility for approval of all

inspection media?

Requirements

D6-51991, Sec 8.1

• Inspection media (paper inspection plans, inspection datasets, CMM programs, Mylars,

media of inspection (MOI) tools, etc…) needs to be traceable to the authority dataset.

• If the inspection media is created by an organization other then supplier Quality

Assurance, there needs to be a documented and audited process approved by QA.

• Describe Inspection Media and method that will ensure that all product features are

planned for inspection

16. Does the supplier have a documented

process to create inspection media from

a 3D model in addition to the 2D

drawing?

Requirements

D6-51991, Sec 8.2, 8.3

• A process to assure accuracy of derivative media (e.g. Mylars, tools, CMS programs,

NC programs) from authority datasets.

• Plotted Mylar media should be validated at each point of use. Ref applicable document

for plotted media (Ref D1-8110-9)

• Inspection media is independently derived from and traceable to the authority dataset.

• Media must be under configuration control.

• Media contains graphics and text sufficient to illustrate inspection operations ,

traceability and QA verification

• Review process (checker, checklist, or peer/team review)

• Media is created by qualified personnel.

• Digital inspection operations are performed by qualified personnel.

• Documentation of the coordinate system, datum targets, and datum features.

17. Is there a process in place to document

FAI’s for product produced from authority

datasets?

Requirements

D6-51991, Sec 8.5

• This question applies to 2D drawings that are not fully dimensioned or partially

dimensioned and requires a dataset for manufacturing and inspection. Customer

provided drawings which have contoured surfaces shall be specifically called out on the

drawings, flag notes or notes list.

• Process for reduced dimension drawings (RDD), minimal dimensioned drawings (MDD),

simplified drawings (SD) etc.) requires supplier to ensure all dimensioned, un-

dimensioned features and general flag note requirements are planned for verification.

• Unique identification of each feature is required. Various acceptable methods are

available to manage this data (e.g. screen prints, supplier drawings & sketches etc.)

• Digital measurement must have guidelines to ensure the appropriate quantity of

individual measurements are taken on the feature being measured (i.e., quantity of

surface points for measurement, CMM hits).

• Supplier responsible to verify 100% of all the feature when using customer drawing and

or datasets

18. Does the supplier document the current

level of hardware configuration, software,

software revisions and other digital

system information (e.g. PTF(s), project

files) required to maintain compatibility

with Boeing supplied datasets and/or data

exchange formats per applicable Boeing

system(s) requirement documents?

Requirements

D6-51991, Sec 9.1

• Determine which Boeing sites send or will send datasets to the supplier. Note: The site

specific data exchange requirements will determine the method of how you audit. (see

PQAA)

• Supplier data exchange software compliant to Boeing site requirements (e.g. encryption,

file transfer protocol (FTP), web connection, etc…)

• Ensure software levels and equipment matches DPD Capability questionnaire.

• See matrix at end of this Guide for site-specific data exchange requirements.

• If system is not compatible, there must be documented process to verify Boeing

received authority data is acceptable before release.

19. Does the supplier verify dataset

translations when a supplier translates

Boeing authority datasets from their as

received format into their manufacturing o

inspection software?

Requirements

D6-51991. Sec 9.2

• When translations of digital datasets occur between CAD systems or digital equipment,

a process must be in place to verify data. Examples of how this can be accomplished

are using IGES_CHK, point cloud method or other software validation processes.

• See matrix at end of this Guide for site-specific data exchange requirements

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Checklist Question What to look for…

A. Digital Product Definition:

20. Does the supplier ensure that when

Tool Design responsibility is flowed

down to sub tier suppliers that the sub-

tier supplier is approved by the

supplier?

Requirements

D6-51991, Sec 10.1.2

• Locate several designed Special Tools. Assure that:

• The tool identification bears a Supplier and/or Boeing Tooling Acceptance Stamp. (A

Boeing stamp may or may not be required depending upon ST Category)

• Authority Design information is identified on the tool and is legible or is available in

Supplier records system.

• Supplier has contractual notes that flow Boeing DPD/MBD requirements to all their

approved sub-tier suppliers.

• Compare list of suppliers receiving datasets to list of suppliers approved to receive

datasets.

• When controlled datasets are provided to sub-tier suppliers, the supplier ensures sub-

tier supplier is in compliance to Boeing ITAR, EAR and contract requirements prior to

approval and release of DPD/MBD datasets.

• Supplier has assessed sub-tiers and ensures the proper capabilities to manage and use

the Boeing DPD/MBD datasets being provided.

• ASL that shows an approval for controlling Tool Design

• Process for approval for Tool Design (Questionnaire with tool design questions)

• Contract language or PO note that flows down requirements from customer

• Supplier performance Metrics for the approved suppliers (What does it take to

disapprove the supplier?)

• Is there a process for protecting Boeing data when it is transferred to sub-tier to

suppliers (secure transfer).

• Where a Boeing provided dataset is provided to a sub-tier supplier, the dataset

transfer must be encrypted.

•

21. Does the supplier have a documented

process to ensure release, acceptance,

identification, security, access and change

control for:

• Tool design datasets

• Tool Inspection datasets

Requirements

D6-51991, Sec 10.1

• There must be a documented process to review, revise and control tooling when

authority dataset changes affect tooling configuration.

• There must be a documented release process and secure storage of released tool

design datasets.

• Digital definition of physical tooling (including templates, check fixtures) must conform to

digital engineering definition or approved tool design.

• Tools and tool design/inspection datasets must be traceable to the authority dataset and

the affected revision.

22. Are digitally defined special tools and

physical inspection media (check

fixtures, templates, etc.) identified and

traceable to the authority tool design

dataset?

Requirements

D6-51991, Sec 10.2

• Special Tooling must contain at a minimum, Tool Identification and the authority design

information.

• Non-Design Special Tooling - The revision level(s) of the Engineering

Drawing/Dataset(s) used to fabricate the tool.

• Designed Special Tooling - The revision level(s) of the Tool Engineering

Drawing/Dataset(s) used to fabricate the tool.

• Ideally, tools should be identified with Authority Design information somewhere on the

tool. Either stamped directly on the tool or on a tag. (Ref UT6907). However, Authority

Design information may also be contained within Supplier records. Locate several

designed Special Tools. Assure that:

• Authority Design information is identified on the tool and is legible or is available in

Supplier records system.

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Checklist Question What to look for…

A. Digital Product Definition:

23. Are special tools and tooling media

accepted and periodically validated to

the authority design at a frequency

determined to ensure accuracy and

repeatability?

Requirements

D6-51991, Sec 10.3

• Special Tooling must periodically be revalidated to its Authority Design requirements.

This revalidation may be known as a PTI. It generally reviews several areas include but

are not limited to:

• Comparison of As Designed configuration to As Built configuration.

• Visual Inspection for wear/damage

• Dimensional Validation

• Randomly sample some Special Tooling that bears Indication of Inspection Status

(Sticker).Check to assure that the due date is somewhere after today.

• Check due date back to Suppliers Inventory and Recall system for due date agreement.

• Observe tool for obvious damage, nicks or de laminations, worn edges, etc.

• A verification plan should be created for each tool or Supplier should have

documentation that describes how verification is performed and what is validated.

24. Does the supplier define training

requirements that:

• Assure competence and maintain

employee training records, including

on-the-job-training, for all DPD system

users.

• Respond to changes to the DPD

process, equipment, or software?

Requirements

D6-51991, Sec 11.0

• This can be a spreadsheet with a listing of personnel or job title that is cross referenced

with the defined training that is required for DPD See example;

• The supplier must have a documented process that ensures the appropriate quality

assurance and other affected personnel responsible for product acceptance have proper

training to use DPD/MBD/Product Acceptance Software for inspection planning,

measuring and product/tool acceptance.

• The supplier must have a documented process that ensures other affected personnel

responsible have proper training to use DPD/MBD when it directly affects their job

function.

• The training must be formally documented and kept on file. This includes OJT when

used as a training tool.

• Look for changes to the training program in response to changes to the DPD process,

equipment, or software.

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Checklist Question What to look for…

B. Model Based Definition MBD

1. Does the supplier’s CAD system

have the ability to view annotation

based on Boeing site-specific

requirements?

Requirements

D6-51991, Sec 9.1

• Determine which Boeing sites send or will send datasets to the supplier. Note: The site

specific data exchange requirements will determine the method of how you audit.

• Supplier data exchange software compliant to Boeing site requirements (e.g. encryption,

file transfer protocol (FTP), web connection, etc…)

• Ensure software levels and equipment matches DPD Capability questionnaire

• Compatibility requirements may involve CAD systems or data exchange software.

• Suppliers need the same Boeing CAD native software version or have the Boeing

approved LEV to view the annotation.

• See matrix at end of this Guide for site specific data exchange requirements. If site is not

listed in matrix, contact Procurement Agent for specific requirements

• This is CAD Code 6 where the model carries 100 percent authority.

2. Does the supplier have a

documented process to create

inspection media from a 3D MBD

model?

Requirements

D6-51991, Sec 8.2,

• Process to determine when manufacturing and/or inspection views/sketches are

needed to supplement authority dataset.

• Obtain measurement values of all product features from the Authority Model

• Supplier should assure only qualified personnel perform digital inspection

• Process to identify/segregate pre-release or reference datasets

• Note: Is supplier utilizing equipment capability (CAD, LEV, and CMS) to

minimize/automate creation of inspection views? Preferred method is to utilize digital

methods vs. creation of 2D media.

•

3. Does the supplier have a process to

ensure verification of all design

requirements of the authority

dataset? (e.g., all defined by feature

control frames, annotation,

specifications, notes and other

specified requirements in the

authority DPD dataset and

associated parts list including

dimensional and other properties)

Requirements

D6-51991, Sec 8.4

• When planning measurements for product acceptance, the suppliers QA must verify

that all design requirements are identified and planned for inspection. Note:

Compliance for this process is best verified by reviewing FAI documentation for a

specific product.

• Measurement process must have guidelines to ensure the appropriate quantity of

individual measurements are taken on the feature being measured (i.e., quantity of

surface points for measurement, CMM hits).

• Process to ensure Key Characteristics identified on authority datasets are measured

and the results are recorded for every unit.

• This should use AS9102 or equivalent as a guideline for product

• Note: Is supplier utilizing equipment capability (CAD, LEV, and CMS) to

minimize/automate creation of inspection views? Preferred method is to utilize digital

methods vs. creation of 2D media.

4. Is there a process in place to

document FAI’s for product

produced from MBD datasets?

Requirements

D6-51991, Sec 8.5

• Process for reduced content datasets (MBD, RDD, SD, etc.) to ensure all

dimensioned, un-dimensioned features and general / flag note requirements are

planned for verification.

• Unique identification of each feature is required. Various acceptable methods are

available to manage this data (e.g. 3D model, screen prints, sketches etc.)

• Measurement planning must have guidelines to ensure the appropriate quantity of

individual measurements are taken on the feature being measured (i.e., quantity of

surface points for measurement, CMM hits).

• Use 9102 as a guideline for product

Note: Compliance for this process is best verified by reviewing FAI documentation for a

specific product or concurrently validating process.

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Checklist Question What to look for…

B. Model Based Definition MBD

5. Does the supplier have a process to

assure sub-tier suppliers’ ability to

work with MBD information?

Requirements

D6-51991, Sec 6.1

• Supplier has assessed sub tiers onsite and ensures the proper capabilities to manage

and use the Boeing DPD/MBD datasets being provided.

• Supplier maintains records of sub tier MBD capabilities (equipment and process)

• Supplier has documented process to ensure sub tier suppliers inspection planning is

compliant when used to accept Boeing product.

• Supplier documented processes ensure sub tier CAD systems/format are verified

when dataset translation occurs.

• Must control sub tier DPD/MBD suppliers to the same standard as prime supplier.

• Utilize the same Boeing DPD/MBD Checklist requirements.

6. Has the supplier identified specific

training requirements for all functions

associated with use and control of

MBD datasets? (e.g. planning,

purchasing, contract review and Mfg

Requirements

D6-51991, Sec 11.1

• This can be a spreadsheet or training Matrix with a listing of personnel or job title that

is cross referenced with the defined training that is required for DPD

• The supplier must have a documented process that ensures the appropriate quality

assurance and other affected personnel responsible for product acceptance have

proper training to use MBD for inspection planning, measuring and product/tool

acceptance.

• The supplier must have a documented process that ensures other affected personnel

responsible have proper training to use MBD when it directly affects their job function.

• The training must be formally documented and kept of file. This includes OJT when

used as a training tool. Their must be a formal quality system training process.

• Look for changes to the training program in response to changes to the DPD/MBD

process, equipment, or software.

• Process to ensure quality assurance or other persons responsible for product

acceptance been brought into the digital measurement and measurement planning

process.

• Process to train and document tasks when product acceptance or media generation is

performed by non QA personnel.

• Process to encouraged and documented OJT.

• Process to provide training for users of CAD, NC, CMS equipment.

• Process to provide training when software changes are implemented

Checklist Question

What to look for…

C. Coordinate Measuring Systems

1. Does the supplier use CMS equipment

for Tooling and or Product

acceptance?

Check all that apply:

Requirements

D6-51991, Sec 7.2

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19

• Articulating Arm - Portable Coordinate Measuring Machine

• Digital Theodolite

• Fixed Coordinate Measurement Machine

• Fixed Scanning Coordinate Measurement Machine

• Indoor Global Positioning System

• Laser Projectors - Optical Layout Template

• Laser Radar

• Laser Scanner

• Laser Tracker

• Numerical Control Machine Inspection using probes or scanners.

• Photo or Video-grammetry

• Other____________________________

Page 10 of 15

Checklist Question

What to look for…

C. Coordinate Measuring Systems

2. Does the supplier have a process to

control critical functions of the CMS?

Requirements

D6-51991, Sec 7.2.1

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19

D6-56202, Sec.11.1

a) Purpose / Scope – Overview or statement of specific equipment and its intended

use.

b) Calibration – Supplier shall define calibration intervals and maintain a system for

periodic maintenance of measurement equipment. The supplier must document

inventory of all specific components used for CMS and OLT measurement that

could affect the integrity of data collection.. This inventory should include and not be

limited to target accessories (e.g. bushings, adapters, sphere mounts, bar/rod,

probing, drift nest, supports, etc.), all reflector types, and weather station

equipment.

c) Product Acceptance Software – Supplier shall perform Product Acceptance

Software testing per section 3.0.

d) Field Checks / Set up – Establish criteria for field checks / set up to ensure data

and system accuracy prior to collecting measurement data.

e) Drift Points / Stability – When environmental conditions, vibration, or stability of the

product being measured could affect measurement data, drift point analysis is

required. A record of drift points measured and acceptance tolerance used, before

and after measurements is required as objective evidence.

f) Temperature Compensation / Scale Factors – When products are measured in an

uncontrolled environment a documented process to compensate for thermal effects

on the objects being measured is required. Verify compensation using a scale bar

of like (product) material before and after measurements. A record of scale bars

measured and acceptance tolerance used is required as objective evidence. The

product dimensional characteristics being verified must meet the engineering

definition requirements as defined in ANSI/ASME Y14.5, ANSI B89.6.2.1993.

g) Establish Coordinate System – Establish criteria for changing the coordinate

system from a local coordinate system to a part or tool coordinate system. (e.g.

tolerances, datum targets, datum features, tooling holes, tool enhanced reference

system or best fit). Establishment of coordinate systems shall be in accordance with

customer engineering definition and ANSI/ASME Y14.5 as applicable.

h) Multiple Station Set-up Criteria – When moving CMS equipment from one location

to another, or combining CMS equipment during a survey, supplier shall document

their process and acceptance tolerance. A minimum of seven adequately

distributed common points used as reference for repositioning/adding the CMS

equipment during a survey shall be verified and recorded as objective evidence.

i) Data Collection Parameters – Establish measurement guidelines and specific

collection parameters for the CMS equipment prior to collecting measurement data.

(e.g. point density, time/distance separation parameters, apex angles, distance

limitations).

j) Data Analysis – Establish guidelines for the evaluation of 3D point data to tool

engineering, engineering datasets, or drawings.

k) Reports – Establish standard process for CMS reports (e.g. job information,

coordinate system establishment, object temperature, scale bars, drift points, data

analysis and measured results). Reports shall be in English and in inches unless

directed otherwise by customer contract.

l) Record Retention – Establish standard process for all inspection and test records to

be archived and retained per customer contract requirements and provided to the

customer upon request.

m) Training – Suppliers shall define training requirements to assure competence and

maintain employee training records, including on-the-job-training, for all CMS users

per section 11.0.

Note: Is supplier utilizing equipment capability (CAD, LEV, and CMS) to

minimize/automate creation of inspection views? Preferred method is to utilize digital

methods vs. creation of 2D media.

Page 11 of 15

Checklist Question

What to look for…

C. Coordinate Measuring Systems

3. Does the supplier maintain

certification/calibration for equipment used

for inspection, including:

● CMS equipment (Fixed and Portable):

● NC equipment with inspection

probe capability used for product

acceptance

● OLT's

● Ply Cutters

● Other equipment used to accept

part attributes (Scale bar, adaptive

tooling, ball bars, etc.)

Requirements

D6-51991, Sec 7.1

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19.

D6-56202, Sec.6.1

• Tractability to Calibration records must be maintained for all CMS equipment & special

target adapters

• CMS equipment must be calibrated at periodic intervals

• Calibration process must meet NIST or equivalent standards.

• Measuring equipment will be physically identified in accordance with certification records

• Process will provide records of date of acceptance/rejection and next maintenance due

date

•

There must be a process to validate probes for CMM prior to use at each probe angle. This

will be performed before each probe is used base on a certified monument(ball).

4. Is there a process in place to validate

Product Acceptance Software (PAS)

independent of the software

developer?

Requirements

D6-51991, Sec 3.1

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19

D6-56202, Sec.6.1, 11.8

Suppliers procedures must include:

• Supplier PAS must be verified prior to product acceptance use.

• The supplier will establish and maintain a procedure independent of the software

developer

• Determine that the software, and subsequent revisions, accomplishes its intended

function.

• A means of identifying approved PAS software.

• Software Security and Storage

5. Does the supplier develop software for

inspection and acceptance of product?

● Is there a documented process to

require creation of plans and

instructions for the building,

configuration management, loading

and testing of “Supplier developed”

product acceptance software?

Requirements

D6-51991, Sec 3.2, 3.3

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19

There must be a documented process for:

• Control of the build/creation of the CMS software

• Approval and certification testing to assure the software meets industry standards.

accuracies

• Configuration management

• Problem and Trouble Shooting

• Manuals and documentation for the Supplier Developed CMS Software

Page 12 of 15

Checklist Question

What to look for…

C. Coordinate Measuring Systems

6. Does the supplier define training

requirements that:

●Assure competence and maintain

employee training records, including

on-the-job-training, for all CMS system

users.

● Respond to changes to the CMS

process, equipment, or software?

Requirements

D6-51991, Sec 11.1

D950-1159-1, Sec. 8.2.B

D33200, Sec. 1.19

D6-56202, Sec.11.3

• There must be specific training requirements that assure operators and inspectors have

been trained on all functions associated with use and control of the CMS

• The training process must have instruction to assure training is provided when changes

to processes, equipment or software occur

• Supplier shall demonstrate CMS capability and compliance to Boeing approved CMS

procedures

• If supplier receives authority dataset to measure product and tooling they must be DPD

approved.

Page 13 of 15

Checklist Question

What to look for…

D. Plotter

1. Are there documented processes for the

control of Mylar plots used as a media

of inspection? Those procedures shall

include at a minimum the following:

● Plotter Calibration

● Verification of engineering definition

● Verification of plot accuracy

● Quality Acceptance Stamping

● Verify accuracy prior to use

Requirements

D6-51991, Sec 8.6.1

• Plotter Calibration

• Plotting equipment should be located in a temperature and humidity controlled

environment.

• Typically plotters come with calibration software, this software should be run and

used to adjust the plotter.

• A Circle, Diamond, Square pattern is preferred as a independent for validation of

proper calibration

• After the plotter has been calibrated then it should be identified with a calibration

sticker and put a scheduled calibration cycle

• Plotting environment should be 68 degrees +/- .002 degrees

• Record of certification test and frequency any adjustments made and result after

adjustment. This is done daily

• Verification of engineering definition

• Plotted media should be under Configuration control and be traceable to authority

dataset

• A process to verify flat patterns

• Derivative media (Model) shall include gridlines or plot points used for verification.

• Plots are not permitted to be used for engineering tolerances < .030 inches

• Verification of plot accuracy

• Process to validate plots at time of creation (Ref D1-8110-9 for example)

• Grid lines or plot points should be +/- .010 across the length of the plot

• Record temp and humidity at the time of plot

• Quality Acceptance Stamp

• Quality should verify the calibration, temp, humidity, and verification of plot accuracy

• Quality should stamp and date and approve the plot for inspection use

• Verify accuracy prior to use

• Plots should be verified prior to each use Sec 8.6

• Temperature compensation (Ref D1-8110-9)

2. Does the supplier define training

requirements that:

● Assure competence and maintain

employee training records, including

on-the-job-training, for all system

users.

● Respond to changes to the Plotter

process, equipment, or software?

Requirements

D6.51991, Sec 11.1

• There must be specific training requirements that assure operators and inspectors have

been trained on all functions associated with use and control of the plotter

• The training process must have instruction to assure training is provided when changes

to processes, equipment or software occur

• Supplier shall demonstrate compliance to Boeing approved plotter procedures

• If supplier receives authority dataset to create plotted media must be DPD approved

Page 14 of 15

Site specific data connection requirements

Site Specific Data Exchange Formats & Delivery Method

Digital Product Definition D6-51991

Site Delivery

Method/Media

CAD Formats

Supported

Synchronization

Requirements

Verification method Viewing MBD

annotation

Specific Program Requirements

1 BCA Long Beach BPN/CITIS

CD-ROM

NX (UG) Native

IGES

NX = Yes (Memo)

IGES = None

NX Native = None

IGES = IGES Check

software

N/A

2 BCA Puget Sound SNET

CD-ROM

CATIA Native V4

CATIA Native V5

IGES

CATIA V4 = Yes (D6-56199)

CATIA V5 = Yes (D6-56199)

CATIA DMU = Yes (D6-

56199)

IGES = None

CATIA Native = None

IGES = IGES Check

software

STEP = Gage Model for

translation

CATIA (annotation

module)

DMU LEV

a) Catia V4 2.4

R1 or DMU

(Project file) with

IGES 737-747-

757 767-777

b) Catia V5 or

DMU 787 &

747-8

3 IDS Anaheim BPN/CITIS

CD-ROM

Message Courier

PIMS web

CATIA Native V5

ADOBE 3D

STEP

NONE As received CATIA Native V5

DMU LEV

Acrobat Viewer

CEEDS/CATIA

4 IDS El Segundo Message Courier Pro/Engineer Native

Product View

STEP

Yes - Quality clause Q029 Pro/Engineer Native = None

ProductView (LEV) = None

As received.

Pro/Engineer (Native

models)

ProductView LEV

5 IDS Fort Walton

Beach

BPN

CD-ROM

CATIA V5

IGES

STEP

None As received N/A

6 IDS Huntington

Beach,

DPD Requirements

BPN/CITIS

CD-ROM

CATIA V4 (a)

UG II all versions

Parasolid

None As received N/A a) 767 Tanker

Offload - Catia V4

2.4 R1 or DMU

with IGES

7 IDS Huntington

Beach,

MBD requirements

BPN/CITIS

CD-ROM

CATIA Native V5 R12

NX Native NX2

Yes- Quality clause Q029H As received Native environment

Page 15 of 15

Site Delivery

Method/Media

CAD Formats

Supported

Synchronization

Requirements

Verification method Viewing MBD

annotation

Specific Program Requirements

8 IDS Huntsville CD-ROM NX (UG) Native

CATIA V5

IGES

NX (UG) = None

Catia = None

IGES = None

NX (UG) Native = None

Catia = None

IGES = IGES Check

software

NX (UG) Native

CATIA Native

N/A

9 IDS Long Beach

(C17)

PSN NX (UG) Native

IGES SUPPAR

STEP

NX (UG) = Yes (PSN

Notification)

IGES = None

STEP = None

NX (UG) Native = None

IGES = IGES Check

Software

STEP = Gage Model for

translation

NX (UG) File as

downloaded from

PSN

IGES SUPPAR

STEP SUPPAR

VisView LEV

10 IDS Mesa BPN/CITIS

CD_ROM

NX (UG) Native

CATIA V5

IGES SUPPAR

IGES

STEP

NX = None

IGES SUPPAR = None

IGES = None

NX (UG) Native = None

IGES = IGES Check

software

NX (UG) File as

received

IGES SUPPAR

VisView LEV

11 IDS Philadelphia BPN/CITIS/TEC

CD-ROM

CATIA Native V4

CATIA Native V5

NX (UG) Native

STEP

STEP SUPPAR

CATIA Native V4 = none

CATIA Native V5 = none

NX (UG) Native = none

STEP = none

STEP SUPPAR = none

As received CATIA (annotation

module)

NX (UG) File as

received

DMU LEV

STEP SUPPAR

12 IDS Puget Sound BPN/CITIS

CD- ROM

CATIA Native V4

CATIA Native V5

IGES

CATIA V4 = None

CATIA V5 = None

IGES = None

As received N/A

13 IDS Southern CA

(C130)

PSN

Message Courier

NX (UG) Native

IGES SUPPAR

STEP

NX (UG)= Yes (PSN

Notification)

IGES = None

STEP = None

NX (UG) Native = None

IGES = IGES Check

Software

STEP = Gage Model for

translation

NX (UG) File as

downloaded from

PSN

IGES SUPPAR

STEP SUPPAR

14 IDS St. Louis BPN/CITIS

CD-ROM

Message Courier

NX (UG) Native

IGES SUPPAR

IGES

STEP

Parasolid

CATIA V5

NX (UG)= None

IGES SUPPAR = None

IGES = None

Catia = Yes (TBD)

As received NX (UG)File as

downloaded

IGES SUPPAR

Catia compatible LEV

a) 767 Tanker

Offload - Catia V4

2.4 R1 or DMU

with IGES

15 IDS Wichita SNET

CD-ROM

3.5" Disk

4mm Cassette

8mm Cassette

1/4" Cassette

36 Track

Cassette

CATIA Native V4

CATIA Native V5

IGES

STEP

CATIA V4 = Yes (D6-56199)

CATIA V5 = Yes (D6-56199)

CATIA DMU = Yes (D6-

56199)

IGES = None

STEP = None

CATIA Native = None

IGES = IGES Check

software

STEP = Gage Model for

translation

CATIA (annotation

module)

DMU LEV