Aerospace Safety and Quality

Course Description

This combined lecture and laboratory course (ETI1853C) introduces students to the principles and practices of safety management and quality assurance as applied in the aerospace, aviation, space, and defense manufacturing industries. Students examine federal regulatory frameworks, industry quality management standards, hazard identification methodologies, and quality control techniques used throughout the aerospace supply chain. The course is designed to prepare students for entry-level roles in aerospace manufacturing, maintenance, repair, and overhaul (MRO) environments where rigorous safety and quality compliance is mandatory. It is classified under the Florida Statewide Course Numbering System (SCNS) in the Engineering Technologies > Industrial Systems Technology taxonomy (prefix ETI) and carries the lab indicator "C," denoting a combined lecture and laboratory format meeting in the same location at the same time.

Learning Outcomes

Required Learning Outcomes

Upon successful completion of this course, students will be able to:

• Explain the structure and requirements of the AS9100D Quality Management System (QMS) standard for aviation, space, and defense organizations.
• Identify and apply the foundational elements of ISO 9001:2015 as they relate to aerospace quality management.
• Perform hazard identification, risk assessment, and risk mitigation procedures in an aerospace manufacturing or MRO environment.
• Demonstrate proper use of personal protective equipment (PPE) and compliance with applicable OSHA regulations and hazardous materials handling procedures.
• Describe and apply inspection and quality control techniques, including methods, work instructions, and documentation for manufactured and assembled aerospace products.
• Explain nonconformance control processes, including material review, corrective action, and disposition of nonconforming hardware.
• Apply root cause analysis and corrective action (RCCA) methods to identify and resolve quality defects.
• Interpret aerospace technical documentation, including drawings, specifications, standards, and work orders.
• Describe the four pillars of a Safety Management System (SMS): Safety Policy, Safety Risk Management, Safety Assurance, and Safety Promotion.
• Recognize industry and regulatory requirements from bodies such as the FAA, EASA, OSHA, and the International Aerospace Quality Group (IAQG).

Optional Learning Outcomes

Institutions may also include the following outcomes based on program emphasis and available resources:

• Compare AS9100 (manufacturing/design), AS9110 (MRO stations), and AS9120 (stockist distributors) and determine which standard applies to a given organizational context.
• Analyze human factors and their impact on quality and safety performance in aerospace operations.
• Apply counterfeit parts prevention strategies and supply chain traceability requirements per AS9100D.
• Conduct a basic quality audit using aerospace quality system documentation and checklists.
• Use computer-based quality analysis tools to evaluate quality data, yields, and rework trends.
• Discuss environmental, health, and safety compliance requirements specific to aerospace manufacturing facilities.

Major Topics

Required Topics

1. Introduction to Aerospace Safety and Quality
   • Role of safety and quality in the aerospace industry
   • Aerospace industry terminology and acronyms
   • Overview of the aerospace supply chain (OEMs, Tier 1/2 suppliers, MRO)
   • Regulatory bodies: FAA, EASA, OSHA, IAQG, SAE International
2. Quality Management Systems (QMS)
   • ISO 9001:2015 foundation and process-based approach
   • AS9100D requirements for aviation, space, and defense organizations
   • QMS documentation: quality manuals, procedures, work instructions, records
   • Configuration management and change control
3. Safety Management Systems (SMS)
   • Four pillars of SMS: Safety Policy, Safety Risk Management, Safety Assurance, Safety Promotion
   • Hazard identification and risk assessment
   • Incident and accident reporting procedures
   • Safety culture and proactive safety behaviors
4. Workplace Safety and OSHA Compliance
   • OSHA General Industry and aerospace-applicable standards
   • Personal protective equipment (PPE) selection and use
   • Hazardous materials identification and handling (SDS/GHS)
   • Lockout/Tagout (LOTO), confined spaces, and fall protection
5. Inspection and Quality Control Techniques
   • Visual, dimensional, and nondestructive inspection methods
   • First article inspection (FAI) per AS9102
   • Measurement system analysis and calibration
   • Acceptance criteria and inspection documentation
6. Nonconformance and Corrective Action
   • Identification and tagging of nonconforming material
   • Material Review Board (MRB) process
   • Root cause analysis (RCA) tools: 5-Why, Fishbone/Ishikawa, Failure Mode and Effects Analysis (FMEA)
   • Corrective action and preventive action (CAPA) systems
7. Risk Management in Aerospace
   • Operational risk management: identification, assessment, and mitigation
   • Product safety and critical item management
   • Supplier quality oversight and risk
8. Technical Documentation and Traceability
   • Reading and interpreting engineering drawings and specifications
   • Part numbering, lot traceability, and serialization
   • Records management and retention requirements

Optional Topics

• Counterfeit parts prevention and detection (AS9100D Clause 8.1.4)
• AS9110 requirements for MRO operations
• AS9120 requirements for stockist distributors
• Statistical Process Control (SPC) and quality data analysis
• Human factors in aerospace quality and safety (CRM, situational awareness)
• Environmental management and sustainability in aerospace manufacturing
• Introduction to AS9100 internal auditing and audit preparation
• Lean manufacturing and continuous improvement (Kaizen, 5S) in aerospace contexts

Resources & Tools

• Standards and Regulations: AS9100D (EN9100:2018), ISO 9001:2015, FAA Advisory Circulars, OSHA 29 CFR 1910 (General Industry), SAE Aerospace Standards
• Reference Texts: Aerospace Quality Management System (QMS) implementation guides; IAQG OPMT (Operations Management Team) publications
• Software Tools: Quality management software (QMS platforms), nonconformance tracking systems, statistical analysis tools (e.g., Minitab)
• Laboratory Equipment: Measurement and inspection tools (calipers, micrometers, gauges), PPE demonstration kits, nondestructive testing (NDT) introductory equipment
• Online Resources: IAQG OASIS (Online Aerospace Supplier Information System) database, OSHA eTools, FAA Safety Team (FAASTeam) resources

Career Pathways

Completion of this course supports preparation for the following entry-level and mid-level roles in Florida's robust aerospace and defense industry:

• Quality Control Inspector – Aerospace manufacturing, assembly, and MRO facilities
• Quality Assurance Technician – Defense contractors, spacecraft manufacturing, and commercial aviation suppliers
• Safety Technician / Safety Coordinator – Aerospace manufacturing plants and launch facilities
• Aerospace Technician – Assembly, testing, and servicing of aircraft, spacecraft, and ground support equipment
• Production / Manufacturing Associate – Companies such as Boeing, Lockheed Martin, Northrop Grumman, L3Harris, Pratt & Whitney, Embraer, and Blue Origin, all of which have a significant Florida presence
• MRO Operations Support – Aircraft maintenance, repair, and overhaul stations

This course also supports articulation into AS or BS degree programs in Aerospace Technology, Industrial Systems Technology, or Engineering Technology at Florida state colleges and universities.

Special Information

Certification Preparation

Course content aligns with the foundational knowledge required for several industry-recognized credentials relevant to the Florida aerospace workforce:

• AS9100D Internal Auditor – Foundational QMS knowledge prepares students for third-party internal auditor training and certification through bodies such as NQA, BSI, or Bureau Veritas.
• ASQ Certified Quality Inspector (CQI) – Course topics in inspection methods, documentation, and nonconformance control align with ASQ CQI exam content areas.
• ASQ Certified Quality Process Analyst (CQPA) – Root cause analysis, FMEA, and corrective action content supports preparation for this ASQ credential.
• OSHA 10-Hour General Industry Card – Workplace safety and OSHA compliance topics directly support completion of the OSHA 10-hour voluntary training program.
• National Center for Aerospace & Transportation Technologies (NCATT) AET – The "C" lab designation and aerospace inspection content support skills assessed in the NCATT Aircraft Electronics Technician and related certification pathways.

Students are encouraged to consult with their program advisor regarding certification exam eligibility requirements and available exam preparation resources at their institution.