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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
derek.alty@bodycote.com ejacklin@fmcallahan.com
Jim Cummings, Vice Chairperson David Michaud, Chairperson
Americas Sector Rep -Fountain Plating Co
-Metal Finishing Co davidm@fountain-plating.com
jimc@metalfinishingco.com
Stu Sherman, Secretary
Bob Custer, -Metallurgical Processing
Americas Sector Rep
ssherman@mpimetaltreating.com
-AAA Plating & Inspection Inc
bob@aaaplating.com
Yoshiomi Sukesada, Asia Sector Rep
Jacky Gualandri -Asahi Kinzoku Kogyo Co. Ltd
Europe Sector Rep ysukesada@akg.co.jp
-SKF Aeroengine France
Jacky.gualandri@skf.com
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
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pr
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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: 9.23.10.1, 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 arshad@sae.org
• 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 ekegerreis@sae.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!
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