Nadcap Supplier Symposium The National Motorcycle Museum in Solihull on 25 th September 2013 The Bodycote Experience UK Perspective Gareth Armstrong Quality Manager UK Bodycote Heat Treatments Limited
Agenda Why we have Nadcap? Quality Management System Requirements A Brief Introduction to Bodycote / Relevant History Our Current Nadcap Status Challenges we Faced / What we Have Learned / Our Current Approach Benefits of Nadcap Disadvantages of Nadcap Suggested Future Opportunities & Recommendations 2
Why do we have Nadcap? Because our Aerospace Customers Mandate it. 3
Quality System Before you consider Nadcap you need to ensure your Quality Management System holds up. Two Alternatives are available to you: 1 AC7004 offered by PRI Cost Saving Opportunity Is ideal if your business solely services direct to Aerospace Nadcap Primes. Check AC7004 is an acceptable QMS with both your Prime & Customer? 2 AS9100 (Revision C) / BS EN ISO 9100: 2009 by a Certification Body Recognised by the I.A.Q.G. 4 Is Internationally Recognised. Foundations built on ISO 9001:2008 usually the minimum customer requirements for none aerospace industries. Multiple / Several / Campus / Complex Certification Structures are available for larger organisations.
QMS and Nadcap is there a Difference? Quality Management Systems are built on the principle of continuous business improvement practices to enhance your company to become successful. Largely YES They both have their place and separate benefits but some areas can over lap. e.g. Internal Auditing of Special Processes & Contract Review Effectiveness. Nadcap is about Technical Compliance to improve / maintain Aircraft Safety and Ensure the supply chain complies to all specified technical requirements. 5
Today Bodycote is the leading provider of thermal processing services worldwide, offering subcontract: Heat Treatment Metal Joining Surface Technology Hot Isostatic Pressing Global Presence Over 190 Specialist Facilities In 26 Countries 6
History Bodycote was founded in 1923, originally a British textile company. Bodycote sole focus switches into Metals Processing & Testing Industries from 1979 onwards. Bodycote has rapidly expanded to present day by successful technology acquisitions and organic growth built on good customer service and a reputation for quality. 1986 Bodycote UK achieve BS 5750 the foundations that developed into today's Quality Management System BS EN ISO 9001:2008 & BS EN 9100 : 2009 on a Multiple Certificate Structure spanning 21 locations. This also today incorporates Nadcap procedures. 2003 Bodycote UK enters the Nadcap Program & drops Civil Aviation Authority registration for HT & EBW. 7
Nadcap Status Today Bodycote (UK) has 15 Nadcap Approvals Spanning across 13 locations. The other 8 facilities service other industries where Nadcap is not required but we do take some of the benefits learned into there daily operations. We have experienced 116 Nadcap audits over the last 10 years. Nadcap approvals cover 3 Special Process Commodity Groups & Specific Testing: Heat Treatments Fusion Welding 8 Coatings
UK Commodity Matrix Heat Treatments HEAT AC7102 AC7102 AC7102 AC7102 AC7102 AC7102 AC7102 AC7102 AC7101 AC7101 TREATMENTS AC7102 / S / 1 / 2 /3 / 4 / 5 / 6 / 7 / 3 / 4 Active Location 2013 HT Base Line Prime Hardness Specific Brazing Aluminium Carburizing Nitriding Testing HIP Induction Hardening Tensile Testing Lab Metallographic & micro Hardness Cambridge YES YES YES NO NO NO YES NO NO NO NO Chard YES YES NO NO YES YES YES NO NO NO YES Chesterfield YES YES NO NO NO NO NO YES NO NO NO Coventry YES YES YES NO NO NO YES NO NO NO NO Derby YES YES NO NO NO NO NO YES NO NO NO Hereford YES YES NO NO NO NO NO YES NO NO NO Macclesfield YES YES NO NO YES NO YES NO NO NO YES Rotherham YES YES NO NO NO NO YES NO NO NO NO Skelmersdale YES YES YES NO NO NO YES NO NO NO NO Stillington YES YES NO NO NO NO YES NO NO NO NO Stockport YES YES YES NO NO YES YES NO NO NO YES Woodford YES YES YES NO NO NO YES NO NO NO NO 9
UK Commodity Matrix Welding & Coatings EBW AC7109 AC7110 / 3 AC7110 / 3 S AC7110 / 12 AC7110 / 12 / S AC7110 / 13 AC7110 / 3 Active Location 2013 Fusion Welding Base Line Electron Beam Welding EBW Prime Specific Welder Qualification Welder Qualification Prime Specific Evaluation of Welds Evaluation of Welds Prime Specific Cambridge YES YES YES YES YES YES YES Skelmersdale YES YES YES YES YES NO NO HVOF / Plasma AC7109 AC7109 / 1 AC7109 / 4 AC7109 / 5 Active Location 2013 Coatings Base Line Thermal Spray Coatings Chemical Stripping of Coatings Coating Evaluation & Lab Practices Newport YES YES YES YES 10
Nadcap NCR Analysis as end 2012 (Includes both Major + Minor) 11 Site Type Total Audit NCR's NCR's per Day NCR's per Check Sheet Cambridge W 3 1.5 0.4 Cambridge HT 1 0.3 0.3 Chard HT 4 1.0 0.7 Coventry HT 2 0.5 0.5 Derby HT 0 0.0 0.0 Macclesfield HT 2 0.7 0.4 Newport C 6 2.0 2.0 Rotherham HT 3 0.8 1.0 Skelmersdale HT 5 1.3 1.3 Skelmersdale W 1 0.5 0.2 Stillington HT 2 0.5 0.7 Stockport HT 3 0.8 0.5 Woodford HT 2 0.5 0.5 UK Average 2.6 0.8 0.6
Jan 2013 All 10 HT & 2 W Sites Simultaneously on Merit 12 Site Type Current Status Jan 2013 Audit Frequency Cambridge W Maintain MERIT 18 Months Cambridge HT Maintain MERIT 24 Months Chard HT Maintain MERIT 18 Months Chesterfield HT (HIP) Approved (New) 12 Months Coventry HT Gain MERIT 18 Months Derby HT Maintain MERIT 24 Months Hereford HT (HIP) Approved (New) 12 Months Macclesfield HT Maintain MERIT 24 Months Newport CT Approved 12 Months Rotherham HT Maintain MERIT 18 Months Skelmersdale HT Maintain MERIT 18 Months Skelmersdale W Maintain MERIT 24 Months Stillington HT Gain MERIT 18 Months Stockport HT Maintain MERIT 18 Months Woodford HT Gain MERIT 18 Months
Culture Changes for Nadcap Implementation Suppliers Must accept all Nadcap check sheet answers are either YES or NO. Any Ambiguity = NO = NCR The site Metallurgist or site Weld Engineer / Coatings Engineer do not have the authority to deviate or accept any deviation from Prime Specifications no matter how trivial. A big culture hurdle to overcome when the process house and site expert Metallurgist is seen as the Processing Technical Expert by both internal & external customers. 13
Challenges to Over come Flow Down The cascading of Prime Specific requirements down through the supply chain to the Special Process Provider. The ideal situation is where all the requirements related to product and Prime Specific Quality Systems requirements flowed down like a cascade via the 1 st Tiers. Unfortunately in the real world it doesn t often work like this and sometimes we have to educate our customers. known as Flow Up How? Implement a Robust Contract Review System. 14
Lesson Learned ~ Robust Contract Review Contract Review is not Commercial: Price Checks & T & C s or Goods Inwards Inspection. Contract Review looks at all the technical / compliance aspects needed to meet both customer & prime specification / drawing requirements and whether we have the capability / capacity to meet them. Be prepared to stand by your Contract Review System until questions are answered satisfactory and in writing from the prime / design authority (not the first tier customer), irrespective of: Urgent Customer Delivery Requirements Aircraft on the Ground All associated pressures applied through the supply chain Parts must be Right First Time & Every Time. Apply a Zero Risk Culture to your Business. Try to Treat all products the same: do not differentiate between Aerospace and Non-Aerospace products at your facility, until all technical requirements are fully understood. 15
Why have we received a audit NCR if it was acceptable at the last audit? Auditor Inconsistency Opinion Interpretation? Clarify in Writing with the 1 Confused st Tier, 2 Prime & nd Tier, 3 rd Tier Prime Customer or Design etc Requirements & Authority Interpretation Frustrated Before Processing. You Need to build good Prime contacts to assist / interpret technical requirements. Special Process Provider Interpretation 16
Lessons Learned Invest / Upgrade in the latest technology examples include: furnace autonomous control remove / reduce the human manual factors / de-skill through process control systems. You need to build Strong Supplier Relationships examples: Thermocouple Manufacturers Equipment Manufacturers Calibration Services Laboratories & Test Houses Train & Develop your People all Levels: Metallurgy Pyrometry Contract Review / Data Card Construction Inspection / Testing / Evaluation Root Cause & Corrective Action Strengthen by Standardisation / Common Approach across locations by sharing information. 17
Benefits of Nadcap Business Security & Retention. Enhanced Reputation for Quality & Technical Excellence. Confidence that Process Controls are of the Highest Standard. Prestige. After 10 years we are finally starting to see, less Prime Audits and more acceptance of just the Nadcap audit. Higher conformance to Prime requirements. 18
Disadvantages of Nadcap Cost of Audits Additional day to day people costs to maintain the necessary quality / conformance level. Potential delay in supply chain Turn Around Times to clarify requirements. Major Drain on site Quality / Technical Resource of Time Spent. Preparing for audits (Perform as many Self Assessments as possible) Participating (Team Approach) Answering NCR s 19
Future Opportunities & Suggestions Mutual Supplier Benefits ~ All Subscribing Special Process Providers need to have more say & involvement into the future program How?. Nadcap audits should not be scheduled by PRI at supplier meetings. PRI should continue to offer Free Training Sessions at Supplier Meetings. Heat Treatment Primes need to work towards one Global Pyrometry / Processing Standard. Like to see Introduced a Flow Down Check Sheet for Tier Manufacturers who purchase Special Processes to verify: Accurate Flow down to sub special process suppliers Adequate verification of purchased services 20
21