Nadcap SUBSCRIBER TUTORIAL

Transcription

1 Jon Steffey Program Manager Informatics Solutions, Research and Development 22 October 2012

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: 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. 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.

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: eauditnet Guides:

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 Maintenance Wing-Hill AFB AgustaWestland Air Force Alenia Aeronautica SpA Avio SpA BAE Systems Military Air Solutions (MAS) BAE Systems Ball Aerospace & Technology Corporation The Boeing Company Bombardier Inc. COMAC Defense Contract Management Agency (DCMA) EADS Corporation Airbus Astrium Cassidian Eurocopter Eaton Aerospace Embraer GE Aviation General Dynamics General Services Administration (GSA) Goodrich Corporation Hawker Beechcraft Corporation Heroux Devtek Inc. (Landing Gear Division) Honeywell Aerospace Israel Aircraft Industries Latecoere Liebherr-Aerospace SAS Lockheed Martin Corporation M7 Aerospace LP MTU Aero Engines GmbH Northrop Grumman Corporation Parker Aerospace Group Raytheon Company Rockwell Collins, Inc. Rolls-Royce Corporation Rolls-Royce PLC SAFRAN Group Sonaca Spirit AeroSystems Textron Inc. Bell Helicopter Cessna Aircraft Company Textron Systems Thales Triumph Group Inc. United Technologies Corporation Hamilton Sundstrand Pratt & Whitney Pratt & Whitney Canada Sikorsky Aircraft Volvo Aero

11 18 Americas Europe Asia TIMELINE OF PRIMES Hawker Beechcraft 1 Pratt & Whitney (US) Pratt & Whitney (Canada) GE Sikorsky 4 RR plc Honeywell RR Corp AVIO Northrop Grumman GSA Hamilton Sundstrand 3 MTU 1 Airbus Vought EADS MTA Bell Eurocopter Helicopter EADS Astrium DCMA EADS Defense Cessna Boeing MD Helicopters 2 Lockheed Martin Goodrich Alenia BAE Systems (US) Rockwell Collins Bombardier SONACA SAFRAN Group (Snecma Services, Hispano-Suizo, Aircelle, Messier- Bugatti, Messier- Dowty, Messier- Services, Labinal, Techspace Aero, Snecma Propulsion Solide, Microturbo, Cinch and Globe Motors) Latecore Liebherr Spirit Textron Systems Ball Aerospace Heroux Devtek BAE MAS Thales Parker Aerospace Group United Space Alliance 2 309th Maint. Wing-Hill AFB Raytheon Co. 2 2 Volvo Aero Corp. Genl. Dynamics IAI 2 Agusta Westland M7 Aerospace Embraer Eaton Aerospace COMAC

12 GOVERNMENT AGENCIES AND CONTRACTOR POSITIONS ON PRI QUALIFICATION PROGRAMS SUBSCRIBER FOR PRI USE AMERICAS EUROPE ASIA 309th MAINTENANCE WING-HILL AFB Hill AFB, UT A (CP, CT, HT, MTL, NMSE, NDT, WLD) AGUSTAWESTLAND Cascina Costa, Italy R (NDT) R (NDT) R (NDT) AIR FORCE WPAFB, OH R (Seals, SLT) Name of Nadcap Subscribing Prime Contractor ALENIA AERONAUTICA SPA Naples, Italy AVIO S.p.A Italy BAE SYSTEMS MILITARY AIR SOLUTIONS (MAS) UK BAE SYSTEMS Nashua, NH U12 U15 R (CP, COMP, HT, MTL, NDT, SE, WLD) R (CP, CT, HT, MTL, NDT, NMSE, WLD) A (CP,CT,WLD) R (CP, COMP, HT, MTL, NDT, SE, WLD) R (CP, CT, HT, MTL, NDT, NMSE, WLD) R (COMP, CP, HT, MTL, NDT, NMSE, WLD) R (CP, COMP, HT, MTL, NDT, SE, WLD) R (CP, CT, HT, MTL, NDT, NMSE, WLD) Special Process and Product mandates to the supplier base in that region BALL AEROSPACE & TECHNOLOGY CORPORATION Boulder, CO A (CP,ETG,WLD) THE BOEING COMPANY (Commercial Airplanes, Intergrated Defense Systems) U11 R (COMP,CP,HT,MTL-Ind.Test labs only, NDT, NMSE-SE only,wld) R (COMP,CP,HT,MTL-Ind.Test labs only, NDT, NMSE-SE only,wld) R (COMP,CP,HT,MTL-Ind.Test labs only, NDT, NMSE-SE only,wld) BOMBARDIER, INC. Dorval, Canada U13 R (COMP, CP, CT, HT, MTL, NDT, NMSE, WLD) R (COMP, CP, CT, HT, MTL, NDT, NMSE, WLD) R (COMP, CP, CT, HT, MTL, NDT, NMSE, WLD) Defense Contact Management Agency (DCMA) (DOD) Alexandrta, VA M (ALL, COMP, ETG, FLU, SEAL, SLT) Airbus U8 R (COMP, CP, ETG, HT, MTL, NDT, NMM, SE, WLD) R (COMP, CP, ETG, HT, MTL, NDT, NMM, SE, WLD) R (COMP, CP, ETG, HT, MTL, NDT, NMM, SE, WLD) KEY: R = Accreditation Required by Prime Letter sent to Suppliers; M = Nadcap Member; A = Accepts Nadcap Accreditation N ote: Not all Subscribers included above; visit eauditnet for full list. Programs listed as of July 2011.

13 INDUSTRY-MANAGED ACTIVE CUSTOMER AUDITS Plan

14 STATUS REPORT SUPPLIER AUDITS Plan Actual Actual Actual Actual Actual AQS Conv Machining Composites CP CT ETG Fluids HT MTL NDT NM NMSE 320 NMMM 9 2 NMMT SE Seals Sealants WLD Preassessments NUCAP Total 4,769 4,791 4,406 4,389 4,015 3,902

15 STATUS OF AUDITS/AUDITORS (FULL TIME EQUIVALENT) Audits Auditors Americas Europe Asia

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) 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 Policy Board of Directors Executive Leaders Legal entity Fiduciary responsibility Set policy Provide the vision

19 BOARD OF DIRECTORS Stan Adachi Director, BDS Supplier Quality Boeing Richard Amato Manager, Manufacturing Engineering GE Aviation Etienne Galan Vice President Quality Snecma David Handley (Chairman) Head of Quality BAE Systems (Operations) Limited Michael Hayward Sector Director Product Quality, Aerospace Systems Northrop Grumman Corp. Mario Langlois Aerospace Quality Director Bombardier Andy Page Global Supplier Development Executive Rolls-Royce plc John Papadopoulos Director Quality & Continuous Improvement United Technologies Corporation David L. Schutt Chief Executive Officer SAE International Kristin Slyker Vice President, Commercial Customer Operations Honeywell Aerospace Junji Tsuji General Manager of Engineering Group Ishikawajima-Harima Heavy Industries Co. Bernard Veyssière Vice President Quality EADS Li Wei General Director, Quality and Safety Department Aviation Industry Corporation of China Steve Wells VP Quality& Continuous Improvement Goodrich

20 PRI/Nadcap Organizational Structure Policy Board of Directors Tactical Nadcap Management Council (NMC) 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) Pascal Blondet, Chairperson Airbus Richard Blyth Rolls-Royce Robert Bodemuller Ball Aerospace & Technology Corp. Katie Bradley Lockheed Martin Tim Brooks M7 Aerospace Christopher Brust DCMA Christian Buck SAFRAN Robert Cashman Parker Aerospace Group Mark Cathey Spirit AeroSystems Javed Cheema Eaton Aerospace Jeff Conrad Cessna Aircraft Company Jim Diamond 309 Maintenance Wing Hill AFB 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 Heather Meyer Cessna Aircraft Company 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 Henry Sikorski Pratt & Whitney Clifford Smith General Services Administration Joe Texteira Hawker Beechcraft Company David Thornhill General Dynamics Neil Tinsley Pratt & Whitney Canada Kevin Ward, Vice Chairperson Goodrich Corporation Kirk Whalen Heroux Devtek George Winchester Northrup Grumman Corwyn Berger EXOVA, Inc. Michael Brandt Alcoa 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. Vern Talmadge Howmet Thermatech Coatings

22 PRI/Nadcap ORGANIZATIONAL STRUCTURE Policy Board of Directors Tactical Nadcap Management Council (NMC) Administrative Staff Technical Technical Experts Determine requirements Develop documents Accept corrective action Final decision on accreditation 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)

23 AGENDA Nadcap Overview Organizational Structure of Nadcap Nadcap Process / eauditnet

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

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 Accreditation Mandated by Nadcap Prime Subscriber Subscriber Action Supplier Action PRI Action 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 INDUSTRY EXPERTS MANAGE ALL KEY STEPS AUDITOR QUALIFICATION & SELECTION 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 AC7XXX Audit Criteria Job Audits Audit Handbook Industry Standards + Prime Requirements

31 INDUSTRY MANAGED PROGRAM AUDIT CHECKLIST PROCESS EVALUTION/ IMPROVEMENT INDUSTRY EXPERTS MANAGE ALL KEY STEPS AUDITOR QUALIFICATION & SELECTION 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 on eauditstaff.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 Process Aerospace Quality Systems (AQS) Chemical Processing (CP) Coatings (CT) Composites (COMP) Elastomer Seals (SEAL) Fluid Distribution Systems (FLU) Heat Treating (HT) Materials Testing Laboratories (MTL) Nonconventional Machining (NMMT) Nondestructive Testing (NDT) Sealants (SLT) Surface Enhancement (SE) Welding (WLD) Experience Summary 60% ISO Lead Assessors; Average 30 Years Experience 70% Have B.S Degree; 22 % Have MS Degree; 11% Have PHD; Average 35 Years Experience 100% Have B.S Degree; 20% Have MS. Degree; 20% Have PHD; Average 30 Years Experience 100% Have B.S. Engineering; 100% Have MS Engineering; Average 15 Years Experience 50% B.S. Engineering; 30 Years Experience 100% Have B.S. Engineering; Average 35 Years Experience 80% Have B.S in Metallurgy/Material Science; 30% Have M.S. in Metallurgy/Material Science; Average 33 Years Experience; Certified Quality Engineer/Auditor 90% Have B.S Degrees; 50% Have MS Degrees; 20% Have PHD; Certified Quality Engineer/Auditor; Average 35 Years Experience 80% Have B.S. Engineering; 40% Have MS Engineering; 20% Have PHD Engineering; Average 32 Years Experience 100% are Level III s for Four (4) Methods; 44% Have Bachelors of Science Degrees; Average 30 years of Experience 50% Have PHD; Average 30 Years Experience 80% Have B.S. Engineering; 40% Have MS Engineering; 20% Have PHD Engineering; Average 32 Years Experience 60% Have B.S Degree; 30% Have MS Degree; Average 34 Years Experience

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

36 Nadcap AUDIT CONTENT 1. Quality Systems 2. Special Process and Product Specific Requirements 3. 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: 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 Calibration: 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 ? (I.e. temperature gages, conductivity meters, voltmeters, rectifiers) Are furnaces used for heat treating Aluminum parts surveyed at the required tolerance and temperature range? Heat Treating Are the FPI dryer ovens calibrated every three months at multiple points across the usable range? NDT Chemical Processing

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

40 NCR CLASSIFICATIONS 1. 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. 2. 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) Nadcap Staff Suppliers Establish Audit Criteria Define Auditor Requirements Interview & Recommend Auditor Contract Auditor Findings Plan/Schedule Audits Supplier Requests Perform Audit Submit C/A Package Review C/A Package Review & Accept C/A Accredit Supplier

44 eauditnet FOR SUBSCRIBERS 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 s regarding your QML supplier audits that were submitted ( 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 INDUSTRY EXPERTS MANAGE ALL KEY STEPS AUDITOR QUALIFICATION & SELECTION 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 User/Primes LIABILITY Does not shift Supplement with PRI Responsible for the process Industry Standards Procedures Oversight Core Values 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 February 2013 Dallas, TX, USA On-line registration available at Reservation information will be posted on the PRI website ( when available.

51 QUESTIONS QUESTION TIME?