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Jon Steffey Program Manager Informatics Solutions, Research and Development 3 June 2013

Jon Steffey Program Manager Informatics Solutions, Research and Development 3 June 2013. AGENDA. Nadcap Overview Organizational Structure of Nadcap Nadcap Process / eAuditNet. DEFINITIONS – PRI. PRI:.

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Jon Steffey Program Manager Informatics Solutions, Research and Development 3 June 2013

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  1. Jon SteffeyProgram ManagerInformatics Solutions, Research and Development3 June 2013

  2. AGENDA • Nadcap Overview • Organizational Structure of Nadcap • Nadcap Process / eAuditNet

  3. DEFINITIONS – PRI • PRI: The Performance Review Institute is a not-for-profit affiliate of SAE whose mission is to: Provide global, unbiased, independent manufacturing process and product assessments and certification services to the mobility industry for the purpose of adding value, reducing total cost and facilitating teaming between primes & suppliers. PRI administers Nadcap.

  4. DEFINITIONS – Nadcap • Nadcap: • Special Processes: are those processes where the parameters are directly influenced by component geometry and/or the results cannot be confirmed by inspection, e.g., NDT, Plating, Heat Treating. • Products: are the manufacturing output of the combination of distinct materials, parts and/or processes which forms a whole, e.g., Composites, Elastomer Seals, Electronics. The leading worldwide co-operative program of major companies designed to manage a cost effective consensus approach to special processes and products and provide continuous improvement within the aerospace and automotive industries.

  5. DEFINITIONS – eAuditNet • eAuditNet: Audit software used to document audit results, attachments, letters, notes, schedules audits, supplier advisories, etc. with the ability to produce reports based on multiple criteria.

  6. HISTORY OF THE PERFORMANCE REVIEW INSTITUTE (PRI) • November 1985: Government/Industry Equal Partners Conference recommends consensus solution to duplication of supplier quality assurance systems • July 1990: PRI incorporated as a Not-For-Profit Trade Association. Launch Nadcap for Aerospace • July 2000: Roll-out of Nadcap Europe • November 2002: Full Launch of eAuditNet • October 2003: Roll-out of Nadcap Asia • April 2008: Roll-out of eQuaLearn • May 2009: Full Launch of eAuditNet 2.0

  7. KEY REFERENCES FOR NEW ATTENDEES • Nadcap Subscriber Tutorial • Attendees Guide • Antitrust (page 7) • Nadcap Personal Code of Ethics and Conflict of Interest (page 7) • PRI Website: www.pri-network.org • eAuditNet Guides: www.eAuditNet.com

  8. SUGGESTIONS FOR NEW ATTENDEES • Attend Task Group mini-orientation at the beginning of each meeting • Introduce yourself to the Task Group Chair and Staff Engineer • Become active in your Task Group; your comments are very important • Provide your feedback from the meeting through the on-line survey

  9. MEMBERSHIP RESPONSIBILITIES • Subscriber members are required to attend Nadcap meetings. If the member is unable to attend, an alternate shall be designated. • Reply to surveys, questionnaires and ballots that are circulated to members. • Carry through sponsorship and coordination of individual projects as assigned. • Prepare checklists for auditing and continuing surveillance. • Review resumes and interview auditors. • Review audit reports. • Comply with the Nadcap Personal Code of Ethics and Conflict of Interest Policy as defined in AS7003. • Safeguard the confidentiality of information that you're exposed to through the Nadcap program.

  10. Nadcap MEMBERS • 309th MaintenanceWing-Hill AFB • AgustaWestland • Air Force • AleniaAeronauticaSpA • Avio SpA • BAE Systems – Military Air Solutions (MAS) • BAE Systems • Ball Aerospace & Technology Corporation • Beechcraft Corporation • The Boeing Company • Bombardier Inc. • COMAC • Defense Contract Management Agency (DCMA) • EADS Corporation • Aerolia • Airbus • Airbus Military/ EADS CASA • Astrium • Cassidian • Eurocopter • Premium AEROTECH • Eaton Aerospace • Embraer • GE Aviation • General Dynamics • General Services Administration (GSA) • GKN Aerospace • GKN Aerospace Sweden AB • Heroux Devtek Inc. (Landing Gear Division) • HoneywellAerospace • Israel Aircraft Industries • Latecoere • Liebherr-Aerospace SAS • Lockheed Martin Corporation • MTU Aero Engines GmbH • Northrop Grumman Corporation • Parker Aerospace Group • Raytheon Company • Rockwell Collins, Inc. • Rolls-Royce • SAFRAN Group • Sonaca • Spirit AeroSystems • Textron Inc. • Bell Helicopter • Cessna Aircraft Company • Textron Systems • Thales • Triumph Group Inc. • United Technologies Corporation • Goodrich (UTAS) Corporation • Hamilton Sundstrand • Pratt & Whitney • Pratt & Whitney Canada • Sikorsky Aircraft

  11. TIMELINE OF PRIMES

  12. GOVERNMENT AGENCIES AND CONTRACTOR POSITIONS ON PRIQUALIFICATION PROGRAMS Special Process and Product mandates to the supplier base in that region Name of Nadcap Subscribing Prime Contractor KEY: R = Accreditation Required by Prime Letter sent to Suppliers; M = Nadcap Member; A = Accepts Nadcap Accreditation Note: Not all Subscribers included above; visit eAuditNet for full list. Programs listed as of July 2011.

  13. INDUSTRY-MANAGED ACTIVE CUSTOMER AUDITS

  14. STATUS REPORT – SUPPLIER AUDITS 2013 Actual through 26 April 2013

  15. STATUS OF AUDITS/AUDITORS (FULL TIME EQUIVALENT) Audits Auditors 4919 4791 4406 4389 98 4015 3870 88 3678 84 80 3295 75 2852 66 66 62 2437 37 1466

  16. NADCAP PROGRAMS • Special Processes • Nondestructive Testing (NDT) • Materials Testing (MTL) • Heat Treating (HT) • Coatings (CT) • Chemical Processing (CP) • Welding (WLD) • Nonconventional Machining & Surface Enhancement (NMSE) • Non Metallic Materials Testing (NMM) • Conventional Machining as a Special Process (CMSP) • Measurement and Inspection (MI) • Systems & Products • Aerospace Quality Systems (AQS): AC7004 • Fluid Distribution Standards (FLU) • Elastomer Seals (SEALS) • Sealants (SLT) • Composites (COMP) • Electronics (ETG)

  17. AGENDA • Nadcap Overview • Organizational Structure • Nadcap Process / eAuditNet

  18. PRI/Nadcap ORGANIZATIONAL STRUCTURE Board of Directors Policy Executive Leaders • Legal entity • Fiduciary responsibility • Set policy • Provide the vision

  19. BOARD OF DIRECTORS • Stan Adachi • Divisional Director, Supplier Quality, Defense, Space, & Security • The Boeing Company • Richard Amato • Manager, Manufacturing Engineering MECoE, Supply Chain Division • GE Aviation • Etienne Galan • Vice-President Purchasing • Snecma (Safran Group) • Michael Hayward • Sector Director International & Logistics Excellence • Northrop Grumman Aerospace Systems • Mario Langlois • Director - Quality Engineering and Safety Office • Bombardier Aerospace • Tony Maguire • Head of Quality, Hawk Aircraft Programmes • BAE Systems PLC • Ron Meester • Vice President, Global Quality • Honeywell Aerospace • Andy Page • Global Engineering & Technology Executive • Rolls-Royce Plc • David L. Schutt, PhD • Chief Executive Officer • SAE International • Junji Tsuji • Manager of Manufacturing Technology Group of Production Planning Department, Aero-Engine and Space Operations • IHI Corporation • Li Wei • General Director, Quality and Safety Department • AVIC • Steve Wells (Chairman) • Vice President of Quality, Aircraft Systems • UTC Aerospace Systems • JianqiangXu • Deputy General Manager of Science, Technology & Quality Department; C919 Program Chief Quality Officer Research Fellow • Commercial Aircraft Corporation of China Ltd. (COMAC)

  20. PRI/Nadcap Organizational Structure Board of Directors Policy Nadcap Management Council (NMC) Tactical Senior quality leaders & managers • Oversee operation of Nadcap • Establish & implement policy & procedures • Task group coordination & development • Identify, develop and deploy improvement

  21. CURRENT Nadcap MANAGEMENT COUNCIL (NMC) • David Bale • Pratt & Whitney Canada • Dietmar Becher • Liebherr Aerospace • Michael Bess • DCMA • Pascal Blondet, Chairperson • Airbus • Richard Blyth • Rolls-Royce • Robert Bodemuller • Ball Aerospace & Technology Corp. • Katie Bradley • Lockheed Martin • Christopher Brust • DCMA • Christian Buck • SAFRAN • Robert Cashman • Parker Aerospace Group • Jim Diamond • 309 Maintenance Wing – Hill AFB • Amie Emerson • Spirit Aerosystems • John Haddock • BAE Systems – MAS • Tim Hayes • General Dynamics • Danieli Hilgemberg • Embraer • Scott Iby • Hamilton Sundstrand • Scott Klavon, Secretary (Non-Voting) • PRI • Ralph Kropp • MTU Aero Engines GmbH • Peter Krutoholow • Sikorsky • Serge Labbe • Heroux Devtek • Daniel Lecuru • Eurocopter • Eric LeFort • Sonaca • Howard Jeff Lott • The Boeing Company • Frank Mariot • Vought Aircraft • Steve McGinn • Honeywell • Robin McGuckin • Bombardier Aerospace • Michael Murray • Beechcraft Corporation • Colby Nicks • Bell Helicopter Textron • Ana Ottani dos Santos • Embraer • Rick Peterson • Rockwell Collins, Inc. • Alberto Portal • EADS – CASA • Mark Rechtsteiner • GE Aviation • Per Rehndell • Volvo Aero Corporation • Brad Richwine • Raytheon Company • Davide Salerno • Alenia Aeronautica SpA • Victor Schonberger • IAI • Lisa Shaw • Eaton Aerospace • Henry Sikorski • Pratt & Whitney • Asa Snitchler • Beechcraft Corporation • Kevin Ward, Vice Chairperson Goodrich Corporation • Kirk Whalen Heroux Devtek • George Winchester Northrup Grumman • Corwyn Berger EXOVA, Inc. • Michael Brandt Alcoa • Mark Brown Kaman Aerospace Group • Tim Crowe Dearborn Precision • Robert Custer AAA Plating & Inspection • Suzanna DeMoss Advanced Chemistry & Technology • Eric Jacklin FM Callahan & Son • David Jones Nex-Tech Processing. • David Michaud Fountain Plating Company • Michael Schleckman Voss Industries, Inc. • Vitorio Stana Avcorp Industries Inc • Vern Talmadge Howmet Thermatech Coatings

  22. PRI/Nadcap ORGANIZATIONAL STRUCTURE Policy Board of Directors AdministrativeStaff Nadcap Management Council (NMC) Tactical Task Groups Special Processes Nondestructive Testing, Materials Testing, Heat Treating, Coatings, Chemical Processing, Welding, NMSE, Non Metallic Materials Testing & Conventional Machining Systems & Products Electronics, Sealants, Elastomer Seals, AQS (AC7004), Fluid Distribution Systems & Composites Supplier Support Committee (SSC) Technical • Technical Experts • Determine requirements • Develop documents • Accept corrective action • Final decision on accreditation

  23. AGENDA • Nadcap Overview • Organizational Structure of Nadcap • Nadcap Process / eAuditNet

  24. Nadcap PROCEDURE HIERARCHY Aerospace Standard which documents the requirements for implementing Nadcap industry consensus-based accreditation programs. AS7003 Quality policy describing the quality system of the organization. QUALITY MANUAL NOP (Nadcap Operating Procedure) Specific procedures by which Nadcap operates. Scope and general operating procedures for each specific Nadcap commodity program. NTGOP (Nadcap Task Group Operating Procedure) NIP (Nadcap Internal Procedure) Specific procedures by which PRI / Nadcap Staff operates. Roles and responsibilities for Nadcap Auditors, and clarifications to facilitate and standardize the audit process. Auditor Handbook

  25. KEY PROCEDURES (Located on eAuditNet, under Nadcap Procedures) • NOP-001: Nadcap Operating Procedure • NOP-006: Supplier Advisory Process • NOP-008: Supplier Merit Program • NOP-011: Audit Failure Process • NTGOP-001: Nadcap Task Group Operating Procedure

  26. THE Nadcap AUDIT PROCESS Subscriber Action Supplier Action PRI Action Accreditation Mandated by Nadcap Prime Subscriber Supplier Requests Audit Audit Scheduled & Auditor Assigned Audit Performed – Auditor Submits Report Re-accreditation Process Supplier Review Certificate Issued to Supplier Task Group Review PRI Technical Staff Review

  27. AUDIT PROCESS • PRI/Supplier Schedules the Audit using eAuditNet.com • Nadcap Checklists and Preparation Instructions available • Encouraged to review the Nadcap Customer Support Initiative (NCSI) presentation on eAuditNet • Perform self-audit • Auditor Conducts the Audit using the applicable Nadcap checklists (located on eAuditNet) • Daily briefing & a final close out meeting at the end of the audit • Auditor Prepares Cover Letter and attaches to audit report (uploaded into eAuditNet) • Supplier has 21 calendar days to initially respond to any findings (7 calendar days for subsequent responses)

  28. EVERY STEP IS MANAGED BY INDUSTRY AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT AUDITOR QUALIFICATION & SELECTION INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS

  29. Nadcap – INDUSTRY WORKING TOGETHER Task Groups (Primes) Nadcap Staff Suppliers Establish Audit Criteria Audit Criteria (AC): Document containing checklists or other surveillance tools to be utilized in the course of determining compliance to established industry standards and prime requirements.

  30. RELATIONSHIP BETWEEN AUDIT CRITERIA (AC), AUDIT HANDBOOK AND PRIME REQUIREMENTS AC7XXXAudit CriteriaJob Audits AuditHandbook Industry Standards + Prime Requirements

  31. INDUSTRY MANAGED PROGRAM AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT AUDITOR QUALIFICATION & SELECTION INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS

  32. AUDIT SELECTION/INTERVIEW/PERFORMANCE • Core and Technical Requirements are Established by Task Group • Potential candidates complete a pre-screening questionnaire oneAuditStaff.com • Interviewed by Task Group • Testing/Certification (Optional) • Training Audits • Review of Training with Report from Lead Auditor • Approval by Task Group • Continual Monitoring through Audit Reviews • Annual PRI/Nadcap Training

  33. AUDITORS CRITICAL TO Nadcap • Highly skilled technical background with average of 30 years experience in the Special process audited • Unlike ISO or EN 9000 based audits, Nadcap auditors do not make the final decision • Nadcap auditor goal is to evaluate and report the technical competency and compliance of the supplier

  34. SAMPLE OF CURRENT AUDITORS & EXPERIENCE

  35. INDUSTRY MANAGED PROGRAM AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT AUDITOR QUALIFICATION & SELECTION INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS

  36. Nadcap AUDIT CONTENT • Quality Systems • Special Process and Product Specific Requirements • Compliance/Job Audits NDT: 3 Witnessed Compliance Jobs per Method and 3 “Paperwork” Completed Compliance Jobs per Method Heat Treating: 2 Long Jobs-8 Short Jobs Materials Lab: Witnessing of All Test Methods Chemical Processing: Minimum of 4 Job Audits Coatings: 2-11 Job Audits (Based on Scope) Welding: 2 Job Audits per Method Nonconventional Machining: 2-10 Job Audits Surface Enhancement: 2-6 Job Audits Composites: 15-30 Job Audits (Based on Manufacturing Flow) Electronics: Complete 1 Job Audit Conventional Machining: 2-14 Job Audits (Based on Scope)

  37. GENERAL FOCUS AUDIT Calibration: Does the supplier define the process employed for the calibration of inspection, measuring and test equipment type, unique identification, location, frequency of checks, check method, acceptance criteria and the action to be taken when results are unsatisfactory? Chemical Processing Heat Treating NDT

  38. TECHNICAL (Nadcap) FOCUS AUDIT Is measuring and test equipment used to control or monitor the control of a process (within parameters) maintained in a calibration system compliant with ISO 10012-1? (I.e. temperature gages, conductivity meters, voltmeters, rectifiers) Are furnaces used for heat treating Aluminum parts surveyed at the required tolerance and temperature range? Are the FPI dryer ovens calibrated every three months at multiple points across the usable range? Calibration: Heat Treating NDT Chemical Processing

  39. INDUSTRY MANAGED PROGRAM AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT AUDITOR QUALIFICATION & SELECTION INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS

  40. NCR CLASSIFICATIONS • Major Nonconformance: • The absence of, or systemic breakdown of, the Process Control and/or Quality Management system. • Any non-conformance where the effect impacts or has the potential to impact the integrity of the product. • Minor Nonconformance: • A non-systemic lapse in conformance to the Process Control and/or Quality Management system.

  41. AUDIT REVIEW PRI Staff Review: • Staff Reviews Package for Completeness • Review Audit Report • Clarification Changes (electronically) - Contact Auditors for Clarification • Review Supplier Corrective Action • Close-Out or request additional information via Forums • Audit Report Package is submitted via eAuditNet for Task Group Review

  42. AUDIT REVIEW Task Group Review: • Task Group decides Procedure for Review • Sub-group review, entire Task Group Review • Task Group Reviews for Correctness • Technical Comments, Supplier Responses, Technical Completeness, Auditor Summary Letter, Identify Additional Findings • Completes Review of Each NCR and dispositions (NCR Status) • Discuss Results with Task Group within Forums • Task Group Votes on Accreditation via On-Line Balloting

  43. Nadcap – INDUSTRY WORKING TOGETHER Task Groups (Primes) Establish Audit Criteria Nadcap Staff Suppliers Interview & Recommend Auditor Define Auditor Requirements Perform Audit Plan/Schedule Audits Contract Auditor Supplier Requests Findings Submit C/A Package Review C/A Package Review & Accept C/A Accredit Supplier

  44. eAUDITNET FOR SUBSCRIBERS – www.eAuditNet.com • Subscribers can use eAuditNet to: • Use ‘Subscriber QML’ to specifically search for your company’s suppliers • Lookup audit details for a supplier including checklist details, nonconformance (NCR) details, and Supplier and Task Group NCR responses • Lookup the current audit status of a supplier • Download or print hard copy checklist(s) • View new or existing Supplier Advisories • View all Nadcap Procedures (NIPs, NOPs, NTGOPs) • eAuditNet Company Administrator, you can use eAuditNet to: • Create new eAuditNet users for your company • Edit current eAuditNet users for your company • Accept or reject eAuditNet users that select your company during registration • Set-up company Users to receive weekly e-mails regarding your QML supplier audits that were submitted (Email Subscription Application) • If you are a Task Group Member, you can use eAuditNet to: • View and discuss supplier audit NCRs • Ballot on supplier audit and merit recommendations An eAuditNet Subscriber’s Audit Review Guide and eAuditNet Company Administrator’s Guide can be downloaded from eAuditNet using Public Documents.

  45. INDUSTRY MANAGED PROGRAM AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT AUDITOR QUALIFICATION & SELECTION INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS

  46. TOP 10 PARAGRAPHS SINCE RELEASE OF COMP AC7118 REV A232 AUDITS

  47. NDT TOP PARAGRAPH REFERENCES AC7114 (SAMPLE – 2010)

  48. QUALITY IMPROVEMENTS FOR SUPPLIERS (SSC 2009 SURVEY RESULTS) An increasing percentage of Nadcap accredited companies report quality improvement in the area(s) related to their Nadcap accreditation(s).

  49. Supplement with PRI Responsible for the ‘process’ • Industry Standards • Procedures • Oversight • Core Values User/Primes “LIABILITY” Does not shift Supplier Conformity Central Information Network “eAuditNet” • Agreements: • Auditors • Suppliers • Users PRI/Nadcap Early Warnings Nadcap-Wide Reduce Risk Reduce Escapes Supplier Responsiveness Consistency in Training

  50. NEXT Nadcap MEETING 21-25 October 2013 Pittsburgh, PA USA On-line registration available at www.pri-network.org Reservation information will be posted on the PRI website (www.pri-network.org) when available.

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