June 15, 2016

Integration procedure - E-11

Set up and implement an integration activity

A. Scope

This document enables an assembly or integration procedure to be prepared for a given product.

B. Fundamentals

The integration of a product consists in assembling the various parts of a product. The integration procedure describes, one-by one, the various stages to be completed, the inspections to be performed or the checks associated with each stage and the facilities required to complete them.

The integration procedures are written by the Assembly, Integration and Test (AIT) activity managers (mechanical, electrical, etc. specialists) and are validated by the Technical Manager of the project (who may be the AITM, by delegation) and the Quality Assurance Manager.

The procedure meets the following objectives:

  • Completely and unambiguously define the integration operations and inspections/measurements to be carried out in compliance with the requirements in the Test Request (TR)/ Test Specification of Requirement (STBE)/AD,
  • Guarantee the conformity of the work carried out,
  • Constitute the means of traceability for the operation carried out,
  • In the case of inspection and test procedures, record the acquired results,

 

C. Typical content

1. Scope

This section contains all the information concerning the purpose and scope. It shall enable at least the following to be briefly defined:

  • the project concerned,
  • the model, system, subsystem, etc.,
  • the personnel or departments involved,
  • the facilities or activities concerned,
  • the operating phase(s) concerned,
  • any specific scopes (nominal cases, degraded cases, etc.).

 

2. Documentation

As far as the procedures are concerned, no mention shall be made of higher-level documents even though their rules are to be observed. (Example: this document, the quality manual, etc.).

2.1 Applicable documents

These are documents that are validated by the Project Manager or his/her representative, and are selected so that they can be used and implemented in direct relation to the content of the document in which they are referenced (test plan, specifications, TR, STBE, Operating Manual (OM), etc.).

2.2 Reference documents

These are the references of the writing sources which restrict or justify the configuration of the document in which they are referenced. These documents can be decisional, regulatory or bibliographic.

3. Definitions/Glossary

The definitions and acronyms are presented in this section.

4. Verification of initial condition

The condition of the equipment and of the facilities required for the operation shall be clearly specified, as shall the specific environment conditions required for this operation. It is recommended that a space should be provided in the procedure to record this information during the operation.

The following sections shall be completed.

4.1 Normal duration of procedure implementation

This information is used to check, before beginning the operations, that enough time is available to carry out the procedure.

The duration and the starting time of the operation phases shall be stated.

4.2 Operational constraints

These are the checks that concern interfaces or incompatibilities other than those relating to safety.

4.3 Safety constraints

These are the checks that are associated with the requirements for the protection of personnel, ground support equipment, facilities and of the environment, and the checks that are associated with protection security requirements, particularly the security of information systems.

4.4 Personnel

This is the exhaustive list of the personnel required, and their qualifications for "implementing" the procedure.

The Integration Quality Assurance Manager, who is involved at the key points, shall be mentioned.

4.5 Documents required

This is the list of documents that are necessary, in addition to the procedure, for its execution.

For example: forms to be filled in, which cannot be included in the procedure, trailer documents during shipment, etc.

4.6 Software - Computerised data

This is the conformity check of the identification of the computerised data media.

4.7 Installations - ground support equipment

These are the verifications, based on methods adapted to the needs of the procedure, of the installations and the essential ground support equipment and tools required for its execution in terms of metrology, calibrations, etc.

5. Content and implementation of the procedure

The procedure for carrying out the operation is described step by step, and unambiguously and chronologically specifies the elementary operations to be carried out. Each step answers the following questions: Who, What, On What, Where, How? and possibly Why?

The software modules run during the execution of the procedure shall be identified in an unambiguous manner, by means of their part number.

In the case where the operation described by the procedure is divided into clearly defined phases, the technical constraints for sequencing these phases shall be clearly identified in the procedure.

In practice, the procedure is most often in table form with several columns featuring, in addition to the chronological number, a description of the task to perform, the expected results, the results obtained or the confirmation of execution.

6. Summary, Conclusion, Changes

This paragraph must allow the operator performing the activity to mention the significant points that arose during the activity (as-run). The Non-conformance reports (NCR), main results, possible improvements to the procedure, possible ambiguities, etc. may be included.

D. Important rules

Concision

A procedure shall include technical instructions that are essential for its implementation by a trained operator.

A procedure shall be written in a language that is perfectly understandable by the operator.

Quality Key Points (QKP)

During the risk analysis for a procedure by an Integration Quality Assurance Manager, in cooperation with the Technical Manager, a decision may be made to introduce Quality Key Points: the function of these key points is, generally, to perform a verification at a given moment in time:

  • because this verification will not be possible later on,
  • in order to establish the traceability of an operation (status, photo, etc.),
  • or because the elements concerned by this Quality Key Point determine the correct result of the operation.

 

These Quality Key Points shall be formalised so as to make them clearly identifiable in the list of instructions. The use of bold type and/or small capitals is recommended.

Critical and high-risk operations

Critical operations (any operation whose incorrect execution, subsequently undetectable, can have an unacceptable impact on the performance of the product) are explicitly identified in the step-by-step procedure. They are executed by the operator in the presence of the Technical Manager and the Quality Manager, all of whom sign the procedure. They cannot delegate their responsibilities.

Operations which involve a risk for the safety of personnel or equipment (high-risk operations) are explicitly identified in the step-by-step procedure and a special note is printed on the first page of the procedure.

Operator Key Points (OKP)

These are aimed at operators in particular and therefore enable the correct implementation of the operations to be checked during the progress phases. Their application is managed in the same way as for quality key points.

Facilities required

It is recommended that a space should be provided in the procedure to record the traceability information concerning the various facilities (traceability of parts, configuration of ground support equipment, names of operators, configuration of documents used).

Expected values

For control or measurement operations, the expected values shall be specified, with their tolerances.

Activities / documentation

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