The aviation sector, known for its stringent safety measures and regulatory frameworks, faces an increasing threat from unapproved parts infiltrating the propulsion supply chain. Such parts can jeopardize aircraft safety, leading to serious operational and safety consequences. To tackle this issue, the Aviation Supply Chain Integrity Coalition (ASCIC) has taken proactive steps, releasing a comprehensive report that outlines a series of actions aimed at mitigating the risks posed by unapproved parts.
This report, a result of a nine-month investigation led by GE Aviation, was prompted by a concerning incident in the UK, where a dealer was accused of selling thousands of engine components with falsified documentation. The coalition, comprising senior executives from major airlines, aircraft manufacturers, engine makers, and maintenance providers, is chaired by Robert Sumwalt, former chairman of the National Transportation Safety Board (NTSB), and John Porcari, former U.S. Department of Transportation deputy secretary. Together, they’ve outlined a path to bolster the supply chain and safeguard aviation safety.
The Growing Threat of Unapproved Parts in Aviation
Unapproved parts are components that have not been manufactured or maintained according to the strict regulations and standards required for aviation use. These parts can slip into the market through counterfeit documentation or via unscrupulous suppliers, leading to compromised safety in aircraft operations. The consequences of such failures can be catastrophic, underscoring the urgent need for comprehensive countermeasures.
According to FAA statistics, unapproved parts are becoming an increasing concern. Between 2016 and 2020, there were more than 400 investigations into counterfeit or unapproved parts within the aviation industry, resulting in fines, part recalls, and even aircraft groundings. Such statistics demonstrate the importance of identifying and mitigating risks before unapproved components find their way into critical systems such as propulsion units.
Key Recommendations from the Aviation Supply Chain Integrity Coalition
The coalition’s report outlines several key actions to reduce the flow of unapproved parts into the supply chain. These recommendations address areas such as supplier approval, documentation processes, training, and the role of accrediting bodies in overseeing the industry.
1. Promoting Use of Approved Suppliers
One of the central recommendations is to encourage the use of suppliers that adhere to the FAA’s Advisory Circular 00-56B. This standard outlines the quality assurance practices that suppliers should follow to ensure their parts are legitimate and meet all safety and regulatory requirements. For international suppliers, adherence to EASA or other equivalent standards is recommended. Ensuring that suppliers meet these standards can significantly reduce the risk of counterfeit parts entering the market.
2. Digitising Documentation and Expanding Use of Digital Signatures
To combat the falsification of documentation, the report calls for digitising critical paperwork related to parts provenance and expanding the use of digital signatures. Digital documentation, stored in secure systems, would create a traceable, tamper-proof record of each part’s journey through the supply chain. This method would make it far more difficult for counterfeiters to introduce unapproved parts into the system, as each component would have an auditable trail from manufacturer to end user.
3. Training Best Practices for Part Inspection and Handling
Another significant focus of the report is on improving the training provided to staff responsible for receiving, inspecting, and handling parts. Personnel must be trained not only to recognise the documentation that accompanies approved parts but also to identify the physical signs of counterfeit or substandard components. Equally important is the need for clear procedures for scrapping or destroying non-usable parts, ensuring they do not re-enter the market.
4. Developing Feedback Channels to Identify Bad Actors
A key aspect of preventing counterfeit parts is the ability to identify and remove dishonest players from the supply chain. The report recommends creating feedback mechanisms that allow companies and individuals to report bad actors to accrediting bodies. These accrediting bodies can then take the necessary steps to blacklist these entities, preventing them from selling unapproved parts to unsuspecting customers.
Impact of Unapproved Parts on Aviation Safety
Unapproved parts not only pose a direct safety risk but also impact operational efficiency and financial stability across the aviation sector. Counterfeit components are often of inferior quality and may not meet the rigorous testing and safety standards required for aviation. This can result in premature wear, failure, or, in the worst cases, catastrophic accidents.
The 2009 crash of an Air France A330 in the Atlantic, while not directly linked to unapproved parts, is an example of the fatal consequences of failures in aviation safety protocols. The crash investigation highlighted the importance of ensuring all components, even those unrelated to the primary cause of the incident, must be of the highest standard. The financial costs associated with recalls, groundings, and legal actions following such events can run into billions, impacting airlines, manufacturers, and maintenance providers alike.
The Role of Regulatory Bodies and Industry in Safeguarding the Supply Chain
Ensuring the integrity of the propulsion supply chain is a shared responsibility between regulatory bodies such as the FAA and EASA, and the industry’s manufacturers, suppliers, and maintenance providers. While regulatory bodies set and enforce standards, it is up to industry players to adopt best practices and maintain stringent oversight of their operations.
The coalition’s report has been shared with both the FAA and EASA, and it is expected that regulatory bodies will adopt and enforce many of the recommendations. Meanwhile, some coalition members have already begun implementing these measures, demonstrating their commitment to maintaining high safety standards.
The Future of Supply Chain Integrity
The aviation industry’s ability to combat the infiltration of unapproved parts hinges on collaboration across the sector. Suppliers, airlines, and regulators must work together to ensure only approved, high-quality components make it into the propulsion supply chain. This will require ongoing vigilance, investment in technology, and adherence to the highest possible standards.
Looking forward, the digitisation of supply chain processes, from manufacturing to maintenance, will play a pivotal role in protecting the industry from counterfeit parts. With secure, blockchain-based systems and robust feedback mechanisms, the industry can expect to see a significant reduction in the number of unapproved parts entering the market. By implementing the recommendations from the ASCIC report, the aviation industry will take a critical step forward in safeguarding both safety and operational efficiency.
Conclusion
The Aviation Supply Chain Integrity Coalition’s report marks an essential milestone in the fight against unapproved parts. By implementing its recommendations, the aviation industry can close existing loopholes and enhance the overall safety and reliability of the propulsion supply chain. With growing risks from counterfeit components, there has never been a more critical time for the industry to unify and take decisive action. Through collaboration, adherence to regulatory standards, and the adoption of cutting-edge digital solutions, the industry can ensure that its high standards of safety and integrity remain intact for the future.
