Nadcap Customer Support Initiative NCSI NCSI Program Goals Slide 2 • Enhance Supplier experience with the Nadcap process throu
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Nadcap Customer Support Initiative (NCSI) NCSI Program Goals Slide 2 • Enhance Supplier experience with the Nadcap process through education • Introduce Supplier to tools available • Describe & affirm Nadcap expectations • Reduce the average number of nonconformances (NCR’s) • Reduce cycle time (time from audit to accreditation) • Increase number of Suppliers on Merit program Important NCSI Slides Slide 3 • Audit Process 18 - 24 • Websites 25,111 • ITAR/EAR 30 - 37 • Supplier Merit 38 - 41 • Failure Policy 42 - 44 • Quality System 55 - 56 • Supplier Advisory 78 - 79 • NCR Responses/RCCA 80 - 103 • Nadcap Meeting Information 108-110 NCSI Agenda Slide 4 • Introduction to PRI and Nadcap • The Nadcap Audit Process • Preparation Steps • During the Audit / Post Audit • Web Tools & Additional Information Nadcap Defined Slide 5 The leading, worldwide cooperative program of major companies designed to manage a cost effective consensus approach to special processes and products and provide continual improvement within the aerospace industry. As of February 2008 Slide 6 GE Aviation Nadcap Members INDUSTRIA de TURBO PROPULSORES Spirit Aerosystems MTU Aero Engines GmbH Vought Aircraft Ind. Rolls-Royce plc DCMA United Space Alliance Lockheed Martin Corp Hamilton Sundstrand Latecoere Pratt & Whitney BAE Systems Military Air Solutions (M.A.S) NASA Goddard Space Flight Center Air Force, WPAFB Bombardier, Inc. Military Transport Rockwell Collins GSA Aircraft Eaton Aerospace MD Helicopters, Inc. AIRBUS Eurocopter The Boeing Company Defense & Rolls-Royce Corporation Securities Systems Liebherr-Aerospace SAS Raytheon Company Astrium AVIO S.p.A Volvo Aero Beechcraft Co Honeywell Aerospace Hawker SAFRAN Group Sikorsky Aircraft Smiths Aerospace Parker Aerospace Group Heroux Devtek Inc SONACA Textron Systems Ball Aerospace & Technology Corp. Alenia Aeronautica SpABAE Systems Goodrich Corporation Bell Helicopter Cessna Aircraft Company ZODIAC Northrop Grumman Corp 309th Maintenance Wing – Hill AFB PRI/Nadcap Organizational Structure Slide 7 Executive leaders •Legal entity PRI Board of •Fiduciary responsibility Policy Directors •Set policy •Provide the Vision 2008 PRI Board of Directors Slide 8 • Robert Briggs • John Saliture (PRI Board Chairman) General Manager Supply Chain Quality Director of Supplier Quality & Technical Performance GE Transportation Northrop Grumman • Wayne Brown • David Schutt Director, BCA Supplier Quality Executive Vice President Boeing SAE International • Scott Collinge • Jerry Tarnacki Director, Business & General Aviation Customer Quality Vice President Quality & Environment, Health & Safety Honeywell Pratt & Whitney • David Handley • Junji Tsuji Head of Quality General Manager of Engineering BAE Systems Military Air Solutions Ishikawajima-Harima Heavy Industries Co. • Lawrence Jenkins • Bernard Veyssière Executive Vice President, Quality & Supplier Vice President Quality Development Rolls-Royce, plc EADS • Mario Langlois • Steve Wells Quality DIrector VP Continuous Improvement Technology & Innovation Bombardier Goodrich • Joël Remond • Wang Yong VP Quality & Continuous Improvement VP, Quality & Safety SAFRAN Group China Aviation Industry Company 1 (AVIC 1) PRI/Nadcap Organizational Structure Slide 9 Policy PRI Board of Directors European Regional Advisory Board Strategic (EURAB) Senior Quality Leaders •Reviews Nadcap resources in Europe •Promotes Nadcap in Europe •Monitors affordability issues as they relate to Nadcap in Europe. European Regional Advisory Body (EURAB) Slide 10 Rossella Andreozzi Ronald Claeys Quan Lac, Chair Alenia Aeronautica Sonaca Rolls-Royce plc SpA Nigel Davies Eric McIlroy Pedro Arroyo Honeywell Bombardier Aerospace Georges-Henri EADS CASA Peter Feind Mesquida Sergio Bilboa Liebherr-Aerospace Latecoere ITP John Haddock Larry O’Dell Pascal Blondet BAE Systems Boeing AIRBUS (Military Air Jean-Michel Poulier Solutions) Eurocopter Nick Brenton David Jimenez Joël Rémond, Vice Goodrich EADS CASA Chair Christian Buck Ralph Kropp Hispano Suiza SA SAFRAN MTU PRI/Nadcap Organizational Structure Slide 11 Policy PRI Board of Directors European Regional Advisory Board (EURAB) Strategic 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 2008 NMC (Nadcap Management Council) Slide 12 Rosella Andreozzi Frank Gritsko Michel Pierantoni, Vice Chairman Sikorsky Aircraft Eurocopter Alenia Aeronautica SpA Manfred Podlech Dianna Berube John Haddock MTU Aero Engines Pratt & Whitney BAE Systems – Military Air Systems Mark Rechtsteiner, Chairperson GE Aviation Pascal Blondet Debra Harrison Airbus DCMA John Reid Bombardier Inc. Robert Bodemuller Tim Hayes Greg Sayler Ball Aerospace Hawker Beechcraft MD Helicopters & Tech. Quan Lac David Sheff Christian Buck Rolls-Royce, plc Eaton Aerospace SAFRAN Group John Shurtleff Eric LeFort Vought Aircraft Industries David Burger Sonaca Rockwell Collins, Inc David Soong Arne Logan Hamilton Sundstrand Mark Cathey The Boeing Company Spirit AeroSystems Camille Valmy Airbus John McBrien Chet Daté, Chairperson GSA Kevin Ward Honeywell Goodrich Aerostructures Group Heather Meyer Kirk Whalen Jim Diamond Cessna Aircraft Company Heroux Devtek Hill AFB Jay Park Larry Wilson Peter Feind Northrop Grumman Lockheed Martin Corp. Liebherr-Aerospace Corporation Nadcap Management Council (NMC) – Supplier Voting Members Slide 13 Corwyn Berger (MTL) David Michaud (SSC) Bodycote Testing Group Fountain Plating Co. Mark Brown (AQS) Michael Schleckman (Welding) Braddock Metallurgical Inc. Voss Industries, Inc. Miguel Gerdel (Composites) Vern Talmadge (Coatings) Thermal Structures, Inc. Howmet Thermatech Coatings Ed Jamieson (Heat Treating) Jerry Wahlin (Chemical Proc.) Bodycote Thermal Processing West AAA Plating & Inspection Inc. Edward Mayer (NM / SE) Meyer Tool Inc. Open: Electronics, NDT, Seals and Sealants PRI/Nadcap Organizational Executive leaders •Legal entity Structure •Fiduciary responsibility •Set policy PRI Board of •Provide the Vision Directors Slide 14 Senior Quality Leaders •Reviews Nadcap resources in Europe European Regional •Promotes Nadcap in Europe Advisory Board (EURAB) •Monitors affordability issues as they relate to Nadcap in Europe. Nadcap Administrative Management Staff Council (NMC) Task Groups Special Processes Supplier Chemical Processing Support Coatings Committee Heat Treating Materials Testing Nonconventional Machining & Senior quality leaders & managers Surface Enhancement •Oversee operation of Nadcap Nondestructive Testing Welding •Establish & implement policy & procedures Technical Experts Systems & Products •Task group coordination & development •Determine requirements AQS (AC7004) •Identify, develop and deploy improvement •Develop documents Composites Distributors •Accept corrective action Electronics •Final decision on accreditation Fasteners Fluid Distribution Systems Sealants, Elastomer Seals Supplier Support Committee Leadership Team (SSC LT) Slide 15 Derek Alty, Europe Sector Rep Eric Jacklin, Americas Sector Rep -Bodycote Heat Treatments Ltd -F.M. Callahan & Son email@example.com firstname.lastname@example.org Jim Cummings, Vice Chairperson David Michaud, Chairperson Americas Sector Rep -Fountain Plating Co -Metal Finishing Co email@example.com firstname.lastname@example.org Stu Sherman, Secretary Bob Custer, -Metallurgical Processing Americas Sector Rep email@example.com -AAA Plating & Inspection Inc firstname.lastname@example.org Yoshiomi Sukesada, Asia Sector Rep Jacky Gualandri -Asahi Kinzoku Kogyo Co. Ltd Europe Sector Rep email@example.com -SKF Aeroengine France Jacky.firstname.lastname@example.org Nadcap Audit Defined Slide 16 The audit is NOT: Conducted by a novice or a generalist A quality system or ISO 9001 audit The audit IS: A thorough assessment for compliance to customer requirements. One of the most comprehensive audits Slide 17 General Focus Audit Does the supplier define the process employed for the calibration of Calibration: 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? NDT Heat Chem Treating Process Technical Focus Audit Are the FPI dryer ovens Are furnaces used for Is measuring and test Calibration calibrated every three heat treating Aluminum equipment used to control : months at multiple parts surveyed at the or monitor the control of a points across the usable required tolerance and process (within parameters) range? temperature range? maintained in a calibration system compliant with ISO 10012-1? (I.e. temperature gages, conductivity meters, voltmeters, rectifiers) NDT Heat Chem Treating Process NCSI Agenda Slide 18 • Introduction • The Nadcap Audit Process • Preparation Steps • During the Audit / Post Audit • Web Tools & Additional Information Begin the Process: Initial Steps Slide 19 Register in eAuditNet.com Contact PRI Scheduling • Complete a preliminary questionnaire and return to Scheduling • Obtain length of audit and cost • Obtain access to Nadcap checklists Schedule Audit Prepare! Nadcap eAuditNet Process Slide 20 1 2 3 4 Request PRI Audit Auditor Suppliers Audit Scheduled Assigned 7 6 9 8 5 Task Group PRI Technical Audit Issue Cert Approval Staff Review Completed Nadcap eAuditNet Process – Reaccreditation Slide 21 1 2 3 4 Supplier Supplier Reaccreditation Auditor receives verifies audit audit scheduled Assigned accreditation date and scope 7 6 9 8 5 Task Group PRI Technical Audit Issue Cert Approval Staff Review Completed Automatic Scheduling Slide 22 • When the Task Group has granted your Nadcap accreditation, eAuditNet will be updated and your accreditation will be listed on the online Qualified Manufacturers List (QML). • At this same time, your next Nadcap audit for the same commodity will be automatically scheduled by eAuditNet. Some can not be auto-scheduled – 85% are! • Please verify the dates and contact the Scheduling Department within 21 days of any changes. – IMPORTANT, a reminder will NOT be sent. Automatic Scheduling – More Details Slide 23 • When an audit is auto-scheduled, you must still accept the Supplier Agreement and designate if there is ITAR/ and or EAR (EC-LR/Restricted) work involved. • Log in to eAuditNet, click Accept Agreement. A list of audits where agreements are not accepted will appear. • Select the audit which you need to accept the agreement and indicate ITAR/ and or EAR (EC-LR/Restricted) status. • This must be done prior to every audit. You will receive reminders. NIP 7-04 Accreditation Term Slide 24 Supplier term of accreditation begins in conjunction with the audit date, not the issue date of the certificate. Accreditation terms are tied to the Nadcap quarterly cycles Reference NIP 7-04 (available on www.eAuditNet.com under User Documents) Audit Month Accreditation expiration September, October, November January 31 December, January, February April 30 March, April, May July 31 June, July, August October 31 Where to Begin and End Slide 25 www.eAuditNet.com • Public Documents • Change of address/Contact sheet (t-frm-11) eAuditNet Supplier Guide & Pre & Post-Audit Tutorials Preparatory Instructions (t-frm-02) – copy attached at each commodity location Audit Handbooks • Miscellaneous Task Group reference and training documents (Auditor training presentations, Pyrometry Reference Guide, etc.) • User Documents • Checklists www.pri-network.org • Nadcap, Supplier Info SSC page – contact details, mentoring and more PRI/Nadcap from a Supplier Perspective Root Cause Corrective Action Tools/Training materials and dates Check both sites often – updates made frequently Slide 26 Checklists User Documents Public Documents User Documents – Important to Read! Slide 27 PRI/Nadcap Internal Procedures (NIP’s) - Documents detailing specific procedures by which PRI/Nadcap Staff operates. Example; Balloting; audit report processing; pre-assessment audits, etc. Nadcap Operating Procedures (NOP’s) - Documents detailing the specific procedures by which Nadcap operates. Example; Audit Failure, Supplier Merit, Supplier Advisories, etc. Nadcap Task Group Operating Procedures (NTGOP’s) Documents developed by PRI describing the scope and general operating procedures for each specific PRI/Nadcap commodity program. Example; NTGOP-001, Appendix 1 = NDT Slide 28 Slide 28 Slide 29 Staff Contacts eAuditNet SSC Page NIP 7-07 EC-LR/Restricted* Materials and Information May 13 2008 Slide 30 The US government has determined that certain products, processes and technical information must be controlled. The documents which control this are: • ITAR – International Traffic in Arms Regulation • EAR – Export Administration Regulations • Exports can occur by seeing or discussing controlled material in addition to obtaining copies of the material *Throughout this presentation when we refer to EC-LR/restricted in this presentation, we are referring to materials, products, technology and information which requires licensing or to which other restrictions apply as per the ITAR or EAR regulations. NIP 7-07(In the process of being changed) Export Controlled Materials and Information Slide 31 The Nadcap process uses both Unrestricted and Restricted personnel (auditors and Staff Engineers) on Nadcap audits On non US audits – licenses are required for either classification of auditors to have access to EC-LR/Restricted information (ITAR) Restricted personnel are non US citizens or green card holders & are not allowed access to EC-LR/Restricted materials anywhere in the world unless they are listed on a license US citizen auditors (Unrestricted) are allowed access to EC-LR materials in the United States without a license Suppliers must know the status of the PRI personnel & keep any Export Controlled material away from Restricted/Unlicensed personnel Auditor status can be found in eAuditNet next to auditors name for assigned audit Best way to determine rest of PRI Staff status is to ask them NIP 7-07 Export Controlled Materials and Information Slide 32 Neither our Nadcap auditors nor PRI Staff (US or non US citizens) are allowed to review any products, information or technology where the end use is nuclear, chemical, biological weapons or rocket systems, Unmanned Aerial vehicles, space launch vehicles, missile or missile technology. Suppliers must ensure that any of this information is not included in any Nadcap audit. Supplier Responsibilities Slide 33 Determine whether you have material, products, technology or information which requires a license or is otherwise restricted by the ITAR or EAR. Contact your customers to be certain. If you have product, information or any other materials restricted by the ITAR or EAR, you must indicate such by answering the ITAR/EAR question “YES” after accepting the supplier agreement when the audit is scheduled. This alerts PRI Scheduling as to whether ITAR/EAR controlled work exists – and guides the assignment of the auditor. Supplier Responsibilities (Con’t) Slide 34 • If you are a non US supplier and you have ITAR or EAR restricted materials – and you do not have a license (Technical Assistance Agreement – TAA) which enables PRI personnel to perform the Nadcap audit – you must review your parts to see that you have enough non EC-LR/Restricted material to complete the audit. You need to communicate this to PRI Scheduling. • You need to complete the embedded Excel spread sheet listing all EC-LR/Restricted materials you have from all primes or customers –on all Nadcap processes. Send this competed form to your PRI Scheduling contact as soon as possible. Supplier Responsibilities (Con’t) Slide 35 • PRI will start the process of securing an approved TAA license as per the regulations such that the next Nadcap audit will not have to exclude the EC- LR/Restricted material. NOTE: If a license for EAR is required it is the responsibility of the supplier to get that license. • NOTE: Only the materials/parts listed on the TAA (and the PRI auditors and Staff) listed on the TAA will be available for the audit. • Suppliers must have a process which keeps all other un licensed/restricted material out of the audit. Supplier Responsibilities (Con’t) Slide 36 General information on Export Control can be found in eAuditNet (Public Documents) and on the Supplier page of the Nadcap website (www.pri-network.org) The May 2nd, 2008 letter on Export control can be found by: clicking on Nadcap, then Supplier info; go to bottom of page Suppliers cannot post or reveal any technical details on EC-LR/Restricted parts in response to any findings in eAuditNet Supplier Responsibilities (Con’t) Slide 37 • EC-LR materials and information is not allowed at Nadcap meetings. At Nadcap meetings ensure that no information is discussed or presented to anyone which is EC-LR/Restricted. • Contact your prime customer if you have any question about the status of information as to Export Control. Supplier Merit (NOP-008) for use on or after 2-JUL-08 Slide 38 • The Supplier Merit Program awards reduced scope and/or extended frequency audits to suppliers based on performance. • Initial audits shall have an accreditation period of 12 months from the first quarter in which it is eligible for review. The first reaccrediation audit shall have an accreditation period of 12 months from the previous expiration. Subsequent reaccreditation audit accreditations shall be either 12, 18, or 24 months based on supplier ability to meet eligibility • Each Task Group shall reach consensus on supplier’s eligibility for participation in the Supplier Merit program. • Supplier merit is visible on the QML. Supplier Merit (NOP-008) – Additional Requirements Slide 39 • To be eligible for an 18 month accreditation, the supplier must meet the following criteria: • Successfully completed Initial and 2 Reaccreditation audits (Merit may be granted for accreditation of 2nd reaccreditation audit) • No Non-Sustaining Corrective actions identified on current or previous audit • No VCA Audits as a result of current or previous audit • No Product Escapes or Level 2 or 3 Supplier Advisories during current or previous audit • No more than 14 Days of Cumulative Supplier Delinquency • Any other justifiable reason agreed to by Task Group Supplier Merit – Additional Requirements (listed in NTGOP) Slide 40 • To be eligible for a 24 month accreditation, the supplier must meet the following criteria: • Previous two accreditations must have been for a minimum of 18 months each • No Non-Sustaining Corrective actions identified on current or previous audit • No VCA Audits as a result of current or previous audit • No Product Escapes or Level 2 or 3 Supplier Advisories during current or previous audit • No major findings • No more than 7 Days of Cumulative Supplier Delinquency • Any other justifiable reason agreed to by Task Group Supplier Merit (NOP-008) – Cont’d Slide 41 4500 100% On Merit Eligible but Not On Merit Percent Eligible on Merit 90% 4000 80% 80% Number of Supplier Commodities 3500 81% 76% 75% 77% 78% 79% 79% 78% 78% 79% 79% 79% 77% 77% 77% 78% 75% 70% Percent Eligible on Merit 72% 3000 697 697 701 700 652 691 673 685 671 679 686 666 60% 711 670 2500 672 695 50% 2000 632 40% 1500 361 30% 2571 2573 2571 2568 2563 2513 2479 2471 2429 2371 2354 2282 2214 2179 2117 2075 1000 20% 1653 175 1184 500 10% 755 0 0% D - 07 D - 08 Ju 07 Ju 08 A - 07 A - 08 A -07 A -08 N -07 N 08 S - 07 S - 08 Ja 04 Ja 05 Ja 06 Fe -07 Fe -08 Ju 07 Ju 08 M 07 M -08 M -07 M -08 O 07 Ja 07 O 08 8 -0 n- n- - n- n- n- - - b- - - - ov ov l l ug ug n ar ar ct n ct ay ay pr pr b ep ep ec ec Ja Trend: Number of merit-eligible suppliers are increasing Failure Policy (NOP-011) For use on or after 2-JUL-08 Slide 42 Modes of Failure: A - Supplier stops audit B – Excessive number of findings C - Severity of findings D - Too many review cycles to complete E – Nonresponsiveness by Supplier • Criteria are not automatic failure points. • Only 4% of all audits conducted in 2007 resulted in failure. • Staff Engineer will contact Task Group if a certain criteria is reached. • Specific criteria determined by Task Group and listed in NOP- 011 appendix. Failure Policy (NOP-011) Criteria Samples Slide 43 Failure Policy (NOP-011) Criteria Samples Slide 44 If an audit meets criteria: • PRI will perform actions as stated in NOP-011 including notifying the Task Group who will review the information to determine if the audit review process should be concluded and the audit failed If an audit is failed: • You must wait a minimum of three months before another audit will be conducted • You must demonstrate corrective actions to the auditor on site at the time of the new audit Sample Average Findings Slide 45 Based on certificates 30 issued for initial audits conducted in 2007. 25 Majors 4 Minors 20 15 3 10 2 2 3 15 4 1 1 5 1 9 4 5 4 2 2 3 0 1 AQS COMP CP CT HT MTL NDT NMSE WLD Average Number of Total Findings Compared to Maximum Number of Total Findings Slide 46 Based on certificates issued for initial audits conducted in 2007. 40 Average 40 Maximum 30 19 22 20 16 13 12 20 12 8 10 19 12 5 8 7 6 0 2 3 3 AQS Comp CP CT HT MTL NDT NMSE WLD Average Cycles Compared to Maximum Number of Cycles Slide 47 Based on certificates issued for initial audits conducted in 2007. 11 9 Average 12 Max 10 7 7 6 6 7 8 6 5 6 4 2 3 3 4 3 4 3 3 2 2 0 AQS Comp CP CT HT MTL NDT NMSE WLD Average Total Cycle Time Slide 48 500 476 Initial Max 450 Initial Min Initial Average Initial Accreditation Cycle Time, Days 400 350 293 300 263 250 188 200 171 168 166 2008 year end goal - 50 150 134 130 130 144 117 119 118 134 139 112 116 106 111 112 100 2007 year end goal - 70 70 69 71 69 61 60 57 60 546158 55 55 43 55 59 53 50 31 17 14 10 12 12 8 9 2 5 5 8 2 5 8 7 2 6 0 1 Ju 7 Ju 8 S 7 O 7 S 8 O 8 M 7 M 08 A 7 A 8 M 7 A 7 M 8 A 8 Ja 7 8 Ja 4 Ja 5 Ja 6 Fe 7 07 N 7 Fe 8 08 N 8 D 7 D 8 -0 -0 -0 -0 -0 l-0 l-0 0 -0 -0 0 -0 -0 -0 -0 -0 -0 0 0 0 0 0 -0 -0 - b- b- n- n- n- n- n- n- n- ug ep ug ep pr pr ay ay ar ec ar ec ct ct ov ov Ju Ju Ja Sample Average Findings Slide 49 Based on reaccreditation 20 audits conducted in 2007. 18 16 Majors Minors 14 3 12 10 2 8 1 2 2 6 2 9 1 4 1 6 2 3 3 3 2 1 2 0 COMP CP CT HT MTL NDT NMSE WLD Average Number of Total Findings Compared to Maximum Number of Total Findings Slide 50 Based on reaccreditation audits conducted in 2007. 62 Average 70 Maximum 60 50 19 20 22 18 28 40 12 30 10 20 12 10 5 7 5 4 5 2 3 0 COMP CP CT HT MTL NDT NMSE WLD Average Cycles Compared to Maximum Number of Cycles Slide 51 Based on reaccreditation audits conducted in 2007. Average 10 Maximum 8 10 7 7 7 7 8 6 5 6 4 2 3 3 3 3 3 3 2 2 0 COMP CP CT HT MTL NDT NMSE WLD Average Total Cycle Time Slide 52 500 Reaccred Max 450 Reaccred Min Reaccred Average 400 Re-Accreditation Cycle Time, Days 359 350 325 300 266 242 250 223 200 156 155164 2008 year end goal - 50 137133 130 150 119 118 115 117 103 118 118 119 100 108 2007 year end goal - 50 78 62 61 61 53 47 53 48 48 47 57 50 29 53 52 46 48 47 44 48 0 2 2 1 1 2 3 1 1 1 0 1 0 2 2 2 3 3 1 Ju -07 Ju -08 A 07 A 08 Ja 04 Ja 05 Ja 06 Fe -07 Ju 7 Fe -08 Ju 8 S -07 O 07 N -07 D -07 Ja 07 S -08 O 08 N -08 D -08 8 M -07 M -07 M -08 M -08 A -07 A -08 0 0 -0 - - n- n- n- n- n- - - - ay ay ar ar n n pr ug ep ct ov ec pr ug ep ct ov ec b b l l Ja Agenda Slide 53 • Introduction • The Nadcap Audit Process • Preparation Steps • During the Audit / Post Audit • Post Audit • Web Tools & Additional Information Relationship between Audit Documents Slide 54 AUDIT Industry AC7XXX HANDBOOK Standards & (if available) AUDIT Prime Clarify Customer CRITERIA Instructions Requirements and + Prime Job Audits (Customer) specification requirements Obtain and download the audit checklist and audit handbook PRIOR to your audit! Quality System Approval Slide 55 Before you can receive a Nadcap special process accreditation, your quality system must be approved: Nadcap recognized quality systems approvals: AS9003 and AS/EN/JISQ 9100 quality system approvals performed by approved registrars - listed in the IAQG Oasis database. (www.iaqg.org/oasis). Product groups require AS9100. ISO/IEC 17025 for testing laboratories (AC7101), must cover the Nadcap scope of accreditation and be from an approved NACLA/ILAC accreditation body. If you have neither of these, you will need a Nadcap AQS audit to AC7004 or AC7006 (labs) to support the special process accreditation. Refer to NOP-002 in www.eAuditNet.com. Quality System Approval (Cont’d) Slide 56 Suppliers scheduling an initial Nadcap audit shall provide PRI a recognized quality system certification prior to the time the audit is entered into eAuditNet or an AC7004 assessment audit shall be scheduled, unless TG requires more than AC7004. For reaccreditation audits, where no existing recognized quality system approval exists, Suppliers shall have two options: • a minimum of 90 days prior to the audit start date schedule an assessment to AC7004, unless TG requires more than AC7004 • provide PRI a valid Quality System accreditation certificate no later than 60 days following the end of the Nadcap audit Suppliers who fail to provide a valid quality system accreditation certificate to PRI by this date shall have the process audit automatically failed without further notice. Pre-Assessment Audit Slide 57 You can schedule a pre-assessment audit using a Nadcap auditor BEFORE your actual Nadcap audit. All the data from the audit will be left with you. No need to close out any findings. The only findings which will be sent to Primes are findings which may potentially impact hardware. Contact PRI Scheduling and/or review NIP 7-06 for more details. Best Investment of Your Time Slide 58 • Use the tools available to you on www.eAuditNet.com • Tutorials where available • Audit Handbooks where available • Checklists • Strengthen your internal audit program – if you do not use the Nadcap checklist you should! Include Job Audits every time. • Get involved in the Nadcap process • Seek guidance from your prime(s). • Familiarize yourself with www.pri- network.org and the tools available • Keep your management informed Job Audit Slide 59 A job audit is a step by step review of all processing on actual hardware evaluating how you meet all customer requirements. Each special process family will have various numbers of job audits to be conducted with the special process checklist. Schedule the Nadcap audit when you will be able to perform as many of the job audits as possible. • Work with scheduling department (internal and PRI’s) • Paper audits may be used but only when absolutely necessary NOTE: Each Task Group has their own requirements you MUST review the Audit Checklist for specific details and speak to the Staff Engineer if you can not provide real part from a Nadcap Prime. Job Audit – Heat Treat Sample Slide 60 Purchase Order Number Customer Part Number Part Description Date of Job/Job Number Material/Material Specification/HT Specification Part Size/Part Thickness Atmosphere/Racking/Thermal Treatment/Quench/Temper/Load Thermocouple/Special Treatments/Stress Relieve/Testing Requirement/Shop Paper/Actual Operator Control & Acceptance Common Findings Slide 61 Job Audits • Customer flowdown • Lack of shop discipline – inform your personnel! • Lack of documentation/Objective evidence • Data transfers Processes requiring approvals not approved (i.e., NDT Techniques or other frozen process) Specification compliance (i.e., frozen process doesn’t meet specification or AMS 2750 compliance) Parts cleaning not in accordance with requirements Testing including periodic Common Findings (Examples)– look on eAuditNet! Slide 62 Chemical Processing: Shop paperwork missing information (part, test piece requirements, etc.) Solution Analysis (log sheet, reviews) Process Observations (operator compliance issues; solutions not at correct temperature when processing, plating current is not equal to the required current, Paint is not mixed for required time, etc.) Composites: Top 10 listing on eAuditNet by checklist paragraph... 10.3.1 Is the manufacturing and/or inspection record complete for all work performed? 10.3.2 Are written work instructions available to the operator and does the procedure(s) accurately reflect the manufacturing process? (Including the proper sequence) Common Findings (Examples) Con’t Slide 63 Heat Treating: Pyrometry continues to be the largest area of findings Top 5 checklist questions with the most findings: 188.8.131.52, 9.20.1, 9.18.1, 9.18.5, 9.20.2. Details on eAuditNet! NDT: Level 2/Level 3 practical exams (Does the candidate document the results of what was detected? Is a check sheet used by the responsible level 3 or delegate?, etc.) Records for the training, qualification and certification of NDT personnel. Level 3 has not approved the person administering the eye examinations. WLD Weld wire control (traceability, storage, purchase) Welder Qualification (eyesight, qualification records, welder not qualified for work being performed, etc.) Training – insufficient evidence Best Practices for Nadcap Success Slide 64 Performing a thorough and complete self-audit. • Record, by question, where in your system you document the requirement • Record, by question, where in your system you have objective evidence of compliance If you cannot write down where in your system you have documentation and what you will show the auditor – the answer is No! Fix all “No’s with complete root cause corrective action prior to audit. Internal Audit – Prepare your System Slide 65 Crucial to Nadcap success! • Review NCR’s from past audits to ensure your corrections are sustaining • Pay attention to past Major NCR’s – especially those with product impact • Review minor findings and observations for trends • Perform a full set of Nadcap job audits • Download and perform an audit to the Nadcap checklist • Confirm that all personnel understand the role they play in making the reaccreditation audit successful and fruitful – merit! • Correct all deficiencies with complete Root Cause Corrective Action BEFORE the auditor arrives PRI Staff Engineer Slide 66 The PRI Task Group Staff Engineer has commodity specific knowledge and expertise. The Staff Engineers review and approve all specified audit packages. Staff Engineers have years of audit review experience – use their expertise before and after your audit Staff Engineer Advice Slide 67 Do not rely on your customer to have found everything in the specification. It is your responsibility to make sure you meet all requirements. Ensure compliance throughout all of your documents. Auditor will check for complete compliance. Pay attention to details, we will. Ask the Staff Engineer questions regarding interpretations – early! More Staff Engineer Advice Slide 68 If there is a conflict between the checklist and your customer requirement, pick the most stringent. Multiple customer requirements will require a more robust system. The specification is the requirement. Procedures must meet all requirements in the specification All process requirements must: • Be Documented • Be Complied with • Have objective evidence of compliance. Of special note: • NDT – Check your exams • HT – Check your pyrometry • CP – Check your periodic testing NCSI Agenda Slide 69 • Introduction • The Nadcap Audit Process • Preparation Steps • During the Audit / Post Audit • Web Tools & Additional Information Scope Verification Slide 70 • During the audit in-briefing, the auditor will log onto eAuditNet.com to conduct a sign-off process to verify the scope of the audit. • You will be asked to review the information to ensure accuracy and make any changes prior to the audit. • After the audit is conducted, no changes can be made to the scope of accreditation. • If you have any questions, contact your customer. Daily Briefings Slide 71 • At the end of each audit day, the auditor will conduct a daily briefing. • Ensure that all findings are understood. • Ensure that proper supplier personnel are in attendance. • Raise any issues or questions you have from the audit. • Open communication between the supplier and auditor is important. If problems arise, contact the appropriate staff engineer. Exit Meeting Slide 72 • Schedule top management to attend. • Make certain that you understand all NCR’s as written – ask questions if you do not understand - this is your chance to ensure the finding will be written clearly. • Review the process requirements and expectations before the auditor leaves. • Open communication between the supplier and auditor is important. If problems arise, contact the appropriate Staff Engineer. NCR Classifications Slide 73 Major Nonconformance: •The absence of, or systemic breakdown of, the Process Control and/or Quality Management system. Or •Any non-conformance where the effect impacts or has the potential to impact the integrity of the product. Examples: incorrect process parameters, missing inspections or processing steps, failure to record required data, missed or out of tolerance calibration; result from failure to implement a corrective action from the previous audit. Minor Nonconformance: Any single system failure or lapse in conformance with the applicable standard or audit criteria. Examples: paperwork oversights, minor changes to procedures for clarification. Refer to PRI Quality Manual available in the User Documents section of www.eAuditNet.com. NCR Review Slide 74 NCR responses may be rejected: By the Staff Engineer • Based on history and experience with Task Group • History with similar findings/responses By the Task Group Each Rejection: Delays your Accreditation Adds to cycle time After the Auditor Leaves Slide 75 We value your feedback – Nadcap is a cooperative program • When you submit your responses you will be prompted to complete an online questionnaire • Complaints must be submitted in writing and will be addressed independently of the audit review process There is an appeals process for NCRs, Staff Engineer decisions, and Task Group decisions • Contact the Staff Engineer for more information If you have an issue that is not being resolved to your satisfaction, you may contact one of the Nadcap Managers: • Arshad Hafeez – Director, Global Business Operations, +1 724 772 1616 x8666 or via email at email@example.com • E.J. Kegerreis – Nadcap Program Manager, Focus on AQS, CP, CT, HT, MTL, NM/SE, NDT, WLD +1 724 772-1616 x4094 or via email at firstname.lastname@example.org Slide 76 Between Audit & Accreditation Slide 77 Yes Supplier submits Staff review of Additional corrective action supplier corrective Information responses action responses Requested? No Yes Additional Information Task Group Requested? Review of Audit Package No Accreditation Supplier Advisory/Early Review Slide 78 If a potential product impact or failure issue is identified all User members will receive an early review notice to look at the audit results. If deemed necessary, a Supplier Advisory will be issued. An advisory is a formal way of communicating concerns regarding documented possible product impact, changes in key personnel, quality systems, equipment, etc. to Nadcap Subscribing Prime Members. Four levels; Preliminary, Potential Product Impact, Safety Alert, Audit Failure, plus one informational. Supplier Advisory/Early Review (Cont’d) Slide 79 Suppliers are encouraged to provide their own comments as part of the advisory (within 5 working days). Before closing the advisory, all other accreditations will be reviewed to determine if the identified issue is systemic and affects other accreditations/ registrations. If the issue is widespread, revocation of current accreditation (if one exists) and other commodity/quality certificates could occur. Refer to NOP-006 for more information. Response Submittals Slide 80 Initial responses are due 21 calendar days from the close of the audit. • Submit in eAuditNet • Submit in accordance with Requirements for Corrective Action Response Requirements (eAuditNet Supplier Guide and www.pri-network.org) For completeness of the audit report, additional information or clarifications may be requested by the Staff Engineer. These responses must be submitted through the Observation Forum on the audit. Slide 81 Response Requirements Slide 82 Help available: www.eAuditNet.com - A link to Response Requirements is attached to the NCR Also: www.pri-network.org -Supplier Info – main page -Supplier Training – additional tools Also: www.eQuaLearn.com to register for RCCA training _ Slide 83 Page 84 Slide 85 EVENT Document Form Team Team Cause Identify Problem Analysis + & Data Root Mistake Determine Causes & Impacts Document Causes Cause: Proofing Direct Root Contributor the + Flow Determine Corrective Actions LAST Chart Specific Sustaining Document C/A cause Mistake Proofing Source Self Successive + in the Loop Back Implement & Follow up Document Follow-up chain! No Solution Yes! Report Acceptable? Done Corrective Action Response Requirements Slide 86 Reply to your Non-conformances in the Supplier Discussion for each NCR in the format below and addressing each item in the ‘Your Reply’ section of the eAuditNet Supplier response forum for each NCR. Immediate Corrective Action Taken (Containment Actions) Root Cause of Nonconformance Impact of all Identified Causes and the Root Cause Action Taken to Prevent Recurrence Objective Evidence is required on ALL findings (see NIP 7-03) for details Effectivity Date For detailed instructions, refer to the eAuditNet Supplier Guide or the Post-Audit eAuditNet tutorial available in the Public Documents section of www.eAuditNet.com. Example – The Non Conformance Slide 87 The procedure for the Qualification and Certification of NDT Personnel (QA-OP-01, Rev J) does not meet NAS 410-2 for the following: A. Incorrect classroom training hours for PT level 2, B. Does not require the level 2 candidate to document the NDT results during the practical examination. C. Allows administration of Practical exams by Level 2’s, D. Does not require the designation of a “Responsible Level 3. E. Does not provide the method for the approval of person(s) administering eye exams, F. Etc…… Immediate Corrective Action Slide 88 Define Immediate Corrective Action Taken Describe the actions taken immediately to: Stop the nonconformance Assess the damage Containment Segregate impacted product Notify as appropriate What action was taken following the issue being discovered during the audit? Did you stop the problem from continuing? Did you contain the problem found? These actions address the immediate or direct cause of the NCR only. Immediate Corrective Action (Cont’d) Slide 89 Define Immediate Corrective Action Taken: NCR Example: The procedure for the Qualification and Certification of NDT personnel does not meet NAS 410-2 Example of an Unacceptable Immediate Corrective Action: The procedure was modified. Example of an Acceptable Immediate Corrective Action: Procedure was reviewed in it’s entirety against the requirements of NAS 410 rev 2 and approved by our responsible Level 3. Procedure attached, note – changes made are specifically identified on our procedure change sheet. Root Cause Slide 90 Define Root Cause of the Nonconformance: Investigate all causes contributing to the nonconformance using fish bone diagrams, 5-why analysis or similar tools. The root cause will be the last logical cause in the chain. Think you got it? Try one more! Only the identified Root Cause should be included in your response (Do not write a thesis). Supplemental information to support your cause analysis may be included as objective evidence if necessary. Root Cause (Cont’d) Slide 91 Define Root Cause of the Nonconformance: NCR Example: The procedure for the Qualification and Certification of NDT personnel does not meet NAS 410-2 Example of an Unacceptable Root Cause: We have been audited by many customers and Nadcap in the past. This has never been a problem and our requirements have been found to be acceptable. Example of an Acceptable Root Cause: Inadequate review of our procedure against the customer/industry standards due to a lack of formal review procedure and lack of assigned personnel to this task. Impact of Identified Causes Slide 92 Define the Impact of all Identified Causes and the Root Cause: What impact did the nonconformance actually have? Consider Were any parts affected? Were any affected parts shipped to the customer? Was the customer contacted? Impact of Identified Causes (Cont’d) Slide 93 Define the Impact: NCR Example: The procedure for the Qualification and Certification of NDT personnel does not meet NAS 410-2 Impact to Hardware: Example of an Unacceptable Impact Statement: No Impact. Example of an Acceptable Impact Statement: No Impact. This discrepancy was procedural only. All NDT records were reviewed and found to be compliant with NAS410 rev 2. Actions Taken to Prevent Recurrence Slide 94 Define the Actions Taken to Prevent Recurrence: define the steps taken to prevent this problem from occurring again. What is the long term action to prevent recurrence? Can only be addressed when the true root cause is known. Do not rush, consider the effectiveness, feasibility, suitability to the company, and the company's budget. Remember, non-sustaining Corrective Actions (CA) become MAJOR findings. By not addressing CA’s adequately there is a potential for a non-sustaining finding on the next audit. This will affect your Supplier Merit. Actions Taken to Prevent Recurrence (Cont’d) Slide 95 Define the Actions Taken to Prevent Recurrence: define the steps taken to prevent this problem from occurring again. NCR Example: The procedure for the Qualification and Certification of NDT Personnel does not meet NAS 410-2. Example of an Unacceptable Action Taken: The procedure is revised. Example of an Acceptable Action Taken: Review teams have been created to address the review of special processes, including NDT. The teams will be comprised of two individuals (for NDT, one of the team members will be the responsible Level 3) and will perform a back to back review of the internal specification against the customer / industry standard for compliance. The reviewers will complete a document review sheet, the procedure will be changed and identified on the review sheet and then forwarded to the relevant personnel for final approval. Objective Evidence Slide 96 Define and Attach Objective Evidence: What information can you provide to demonstrate the RCCA process you applied to the NCR? Objective evidence is required for Major & Minor NCR’s except minor NCR’s accepted (not closed) onsite by the auditor Note: It is expected that the supplier clearly define the root cause corrective action taken. If a procedure is changed, clearly specify what the change was. • Don’t forget to identify the specific actions taken to resolve the nonconformance(s), (e.g., exact text of procedure change, text of stamp to be ordered, etc.) –Objective evidence should be attached electronically in www.eAuditNet.com or submitted by U-fax. –A U-fax directory is located in the Public Documents section of www.eAuditNet.com –Contact the Staff Engineer with any questions. • If you change or create a procedure, implement a new system or method, perform training, propose audits, develop new checklists - SHOW THIS. It may prevent another review cycle. REMEMBER: Do not attach information that discloses Export Controlled details. Objective Evidence (Cont’d) Slide 97 Define and Attach Objective Evidence: NCR Example: The procedure for the Qualification and Certification of NDT personnel does not meet NAS 410-2 Objective Evidence: Example of Unacceptable Objective Evidence: See attached revised procedure. Example of Acceptable Objective Evidence: See attached revised procedure (QA-OP-01, Rev K) for the training and approval of NDT Personnel. Note: Includes approval by the responsible Level 3. See attached procedure (QA-01 Rev B) addressing the addition of the specification review teams. See attached completed document review sheet for QA-OP-01 against NAS410 rev 2. See attached training log sheet for affected personnel. Corrective Action Response Requirements (Cont’d) Slide 98 Effectivity Date: When will the corrective actions be completely implemented? (Accreditation generally cannot be issued until after this date.) Corrective Action Problems Slide 99 Not supplying all the necessary objective evidence, e.g. copy of revised procedure, procedure approval, copy of revised process control log, evidence of training, etc. Some aspect of the Root Cause Corrective Action (RCCA) not addressed adequately. Immediate corrective action taken Root cause Impact to hardware Action taken to prevent recurrence Objective evidence Information not provided within the defined time frame Corrective Action – More details Slide 100 If you have a problem or do not understand how to address an NCR, refer to the tutorials provided underneath the NCR on the supplier discussion screen. “Click here for instructions on How to respond to NCR. Additionally, a Root Cause Corrective Action tutorial is available at http://pri- network.org/training/frameset1.htm” Call the Staff Engineer! If you need clarification on a request for more information, a phone call may save you an additional review cycle. If you will not be able to meet the procedural time frames for responses...extensions can not be granted but communication about WHY a date is missed is important. If Your Response is Not Accepted Slide 101 You have 7 calendar days to respond to the Staff Engineer request for additional information. If the Staff Engineer details a specific request: • Review and comply with the entire request. Your response will not be accepted until all items are addressed. In the event of a generic rejection, i.e., “Readdress Root Cause” • Review the Requirements for Submittal of Corrective Action Responses and make certain you are complying with these requirements. Call the Staff Engineer for clarification. Repetitive rounds of responses are the largest contributor to cycle time, and can lead to failure. Response Due Dates Slide 102 No extensions to the responses requirements of 21/7 calendar days can be granted. This has always been the procedural requirement. An informal extension process existed, but to ensure the process is equitable for all, a formal process was established. All suppliers now have up to 45 days of cumulative lateness in responding. Lateness is viewable on the Prime QML. If you use any of this time, your response is considered late. Using late time COULD affect merit as the Supplier Merit procedure (NOP-008) requires timely response to NCR’s. Email reminders are sent to Suppliers (15/30 days late, 45 days = failure notice). Avoid Repetitive NCR’S! Slide 103 Involve all personnel that will have the responsibility to fix, implement and monitor the corrective actions. Issue notifications throughout all company departments when policies/procedures are changed as a result of corrective action responses. Ensure that more than one person within the company is totally familiar with past and present Nadcap audits and NCR’s. Create a process to ensure Corrective Actions for all NCR’s - major or minor - have been implemented and are monitored, as part of the internal audit process. Management involvement and monitoring is mandatory! (AS9100) Do not attempt quick fixes - even for minor non conformances. If quick fixes are accomplished there should be a process within the company on how these are accomplished and what the limitations are. NCSI Agenda Slide 104 • Introduction • The Nadcap Audit Process • Preparation Steps • During the Audit • Post Audit • Web Tools & Additional Information eAuditNet Information Slide 105 • Keep your email address current to ensure you receive important emails related to your audit. • If there is a change in your contact information, inform the PRI Scheduling Department. • Do not reply to automated emails received from eAuditNet – there are contacts listed in the email. • For eAuditNet Support, refer to the Public Documents section for User Guides or contact the Help Desk at +1 724 772 1616 x8679 or via email at eAuditNetsupport@sae.org Page 106 Page 107 Nadcap Meeting Information Slide 108 Available at www.pri-network.org Minutes & Agendas • Keep up with Task Group activities • Participate in Task Group decisions Plan to attend Open Meeting – Suppliers are always welcome Closed meeting times for User Members only are necessary to discuss proprietary supplier company accreditation issues such as appeals, findings, etc. SSC Meeting Information Slide 109 Operates independently of the Task Groups – focus on overall issues common to suppliers – not technical or Task Group specific Attend the Supplier Support Committee (SSC) meeting to learn about ongoing projects: • Metrics • Survey Get involved – Join the SSC! Volunteers Needed! Page 110 Important Websites Slide 111 www.pri-network.org www.eAuditNet.com www.eQuaLearn.com Key Points Slide 112 Conduct a thorough and complete self-audit to the checklist. • Take this audit seriously. Your customers do. • Be prepared. Use the web tools available to assist you. Complete a thorough and complete root cause analysis and document this in your NCR responses in the appropriate format Share this information with others!