Jon steffey program manager informatics solutions research and development 3 june 2013
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Jon Steffey Program Manager Informatics Solutions, Research and Development 3 June 2013. AGENDA. Nadcap Overview Organizational Structure of Nadcap Nadcap Process / eAuditNet. DEFINITIONS – PRI. PRI:.

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Jon steffey program manager informatics solutions research and development 3 june 2013

Jon SteffeyProgram ManagerInformatics Solutions, Research and Development3 June 2013


Agenda

AGENDA

  • Nadcap Overview

  • Organizational Structure of Nadcap

  • Nadcap Process / eAuditNet


Definitions pri

DEFINITIONS – PRI

  • PRI:

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


Definitions nadcap

DEFINITIONS – Nadcap

  • Nadcap:

    • Special Processes: are those processes where the

      parameters are directly influenced by component geometry and/or the results cannot be confirmed by inspection, e.g., NDT, Plating, Heat Treating.

    • Products: are the manufacturing output of the combination of distinct materials, parts and/or processes which forms a whole, e.g., Composites, Elastomer Seals, Electronics.

The leading worldwide co-operative program

of major companies designed to manage a cost effective consensus approach to special processes and products

and provide continuous improvement within the aerospace

and automotive industries.


Definitions eauditnet

DEFINITIONS – eAuditNet

  • eAuditNet:

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


History of the performance review institute pri

HISTORY OF THE PERFORMANCE REVIEW INSTITUTE (PRI)

  • November 1985: Government/Industry Equal Partners Conference recommends consensus solution to duplication of supplier quality assurance systems

  • July 1990: PRI incorporated as a Not-For-Profit Trade Association. Launch Nadcap for Aerospace

  • July 2000: Roll-out of Nadcap Europe

  • November 2002: Full Launch of eAuditNet

  • October 2003: Roll-out of Nadcap Asia

  • April 2008: Roll-out of eQuaLearn

  • May 2009: Full Launch of eAuditNet 2.0


Key references for new attendees

KEY REFERENCES FOR NEW ATTENDEES

  • Nadcap Subscriber Tutorial

  • Attendees Guide

    • Antitrust (page 7)

    • Nadcap Personal Code of Ethics and Conflict of Interest (page 7)

  • PRI Website: www.pri-network.org

  • eAuditNet Guides: www.eAuditNet.com


Suggestions for new attendees

SUGGESTIONS FOR NEW ATTENDEES

  • Attend Task Group mini-orientation at the beginning of each meeting

  • Introduce yourself to the Task Group Chair and Staff Engineer

  • Become active in your Task Group; your comments are very important

  • Provide your feedback from the meeting through the on-line survey


Membership responsibilities

MEMBERSHIP RESPONSIBILITIES

  • Subscriber members are required to attend Nadcap meetings. If the member is unable to attend, an alternate shall be designated.

  • Reply to surveys, questionnaires and ballots that are circulated to members.

  • Carry through sponsorship and coordination of individual projects as assigned.

  • Prepare checklists for auditing and continuing surveillance.

  • Review resumes and interview auditors.

  • Review audit reports.

  • Comply with the Nadcap Personal Code of Ethics and Conflict of Interest Policy as defined in AS7003.

  • Safeguard the confidentiality of information that you're exposed to through the Nadcap program.


Nadcap members

Nadcap MEMBERS

  • 309th MaintenanceWing-Hill AFB

  • AgustaWestland

  • Air Force

  • AleniaAeronauticaSpA

  • Avio SpA

  • BAE Systems – Military Air Solutions (MAS)

  • BAE Systems

  • Ball Aerospace & Technology Corporation

  • Beechcraft Corporation

  • The Boeing Company

  • Bombardier Inc.

  • COMAC

  • Defense Contract Management Agency (DCMA)

  • EADS Corporation

    • Aerolia

    • Airbus

    • Airbus Military/ EADS CASA

    • Astrium

    • Cassidian

    • Eurocopter

    • Premium AEROTECH

  • Eaton Aerospace

  • Embraer

  • GE Aviation

  • General Dynamics

  • General Services Administration (GSA)

  • GKN Aerospace

  • GKN Aerospace Sweden AB

  • Heroux Devtek Inc. (Landing Gear Division)

  • HoneywellAerospace

  • Israel Aircraft Industries

  • Latecoere

  • Liebherr-Aerospace SAS

  • Lockheed Martin Corporation

  • MTU Aero Engines GmbH

  • Northrop Grumman Corporation

  • Parker Aerospace Group

  • Raytheon Company

  • Rockwell Collins, Inc.

  • Rolls-Royce

  • SAFRAN Group

  • Sonaca

  • Spirit AeroSystems

  • Textron Inc.

    • Bell Helicopter

    • Cessna Aircraft Company

    • Textron Systems

  • Thales

  • Triumph Group Inc.

  • United Technologies Corporation

    • Goodrich (UTAS) Corporation

    • Hamilton Sundstrand

    • Pratt & Whitney

    • Pratt & Whitney Canada

    • Sikorsky Aircraft


Timeline of primes

TIMELINE OF PRIMES


Government agencies and contractor positions on pri qualification programs

GOVERNMENT AGENCIES AND CONTRACTOR POSITIONS ON PRIQUALIFICATION PROGRAMS

Special Process and Product mandates to the supplier base in that region

Name of Nadcap Subscribing Prime Contractor

KEY: R = Accreditation Required by Prime Letter sent to Suppliers; M = Nadcap Member; A = Accepts Nadcap Accreditation

Note: Not all Subscribers included above; visit eAuditNet for full list. Programs listed as of July 2011.


Industry managed active customer audits

INDUSTRY-MANAGED ACTIVE CUSTOMER AUDITS


Status report supplier audits

STATUS REPORT – SUPPLIER AUDITS

2013 Actual through 26 April 2013


Status of audits auditors full time equivalent

STATUS OF AUDITS/AUDITORS (FULL TIME EQUIVALENT)

Audits

Auditors

4919

4791

4406

4389

98

4015

3870

88

3678

84

80

3295

75

2852

66

66

62

2437

37

1466


Nadcap programs

NADCAP PROGRAMS

  • Special Processes

    • Nondestructive Testing (NDT)

    • Materials Testing (MTL)

    • Heat Treating (HT)

    • Coatings (CT)

    • Chemical Processing (CP)

    • Welding (WLD)

    • Nonconventional Machining & Surface Enhancement (NMSE)

    • Non Metallic Materials Testing (NMM)

    • Conventional Machining as a Special Process (CMSP)

    • Measurement and Inspection (MI)

  • Systems & Products

    • Aerospace Quality Systems (AQS): AC7004

    • Fluid Distribution Standards (FLU)

    • Elastomer Seals (SEALS)

    • Sealants (SLT)

    • Composites (COMP)

    • Electronics (ETG)


Agenda1

AGENDA

  • Nadcap Overview

  • Organizational Structure

  • Nadcap Process / eAuditNet


Pri nadcap organizational structure

PRI/Nadcap ORGANIZATIONAL STRUCTURE

Board of Directors

Policy

Executive Leaders

  • Legal entity

  • Fiduciary responsibility

  • Set policy

  • Provide the vision


Board of directors

BOARD OF DIRECTORS

  • Stan Adachi

    • Divisional Director, Supplier Quality, Defense, Space, & Security

    • The Boeing Company

  • Richard Amato

    • Manager, Manufacturing Engineering MECoE, Supply Chain Division

    • GE Aviation

  • Etienne Galan

    • Vice-President Purchasing

    • Snecma (Safran Group)

  • Michael Hayward

    • Sector Director International & Logistics Excellence

    • Northrop Grumman Aerospace Systems

  • Mario Langlois

    • Director - Quality Engineering and Safety Office

    • Bombardier Aerospace

  • Tony Maguire

    • Head of Quality, Hawk Aircraft Programmes

    • BAE Systems PLC

  • Ron Meester

    • Vice President, Global Quality

    • Honeywell Aerospace

  • Andy Page

    • Global Engineering & Technology Executive

    • Rolls-Royce Plc

  • David L. Schutt, PhD

    • Chief Executive Officer

    • SAE International

  • Junji Tsuji

    • Manager of Manufacturing Technology Group of Production Planning Department, Aero-Engine and Space Operations

    • IHI Corporation

  • Li Wei

    • General Director, Quality and Safety Department

    • AVIC

  • Steve Wells (Chairman)

    • Vice President of Quality, Aircraft Systems

    • UTC Aerospace Systems

  • JianqiangXu

    • Deputy General Manager of Science, Technology & Quality Department; C919 Program Chief Quality Officer Research Fellow

    • Commercial Aircraft Corporation of China Ltd. (COMAC)


Pri nadcap organizational structure1

PRI/Nadcap Organizational Structure

Board of Directors

Policy

Nadcap Management Council (NMC)

Tactical

Senior quality leaders & managers

  • Oversee operation of Nadcap

  • Establish & implement policy & procedures

  • Task group coordination & development

  • Identify, develop and deploy improvement


Current nadcap management council nmc

CURRENT Nadcap MANAGEMENT COUNCIL (NMC)

  • David Bale

    • Pratt & Whitney Canada

  • Dietmar Becher

    • Liebherr Aerospace

  • Michael Bess

    • DCMA

  • Pascal Blondet, Chairperson

    • Airbus

  • Richard Blyth

    • Rolls-Royce

  • Robert Bodemuller

    • Ball Aerospace & Technology Corp.

  • Katie Bradley

    • Lockheed Martin

  • Christopher Brust

    • DCMA

  • Christian Buck

    • SAFRAN

  • Robert Cashman

    • Parker Aerospace Group

  • Jim Diamond

    • 309 Maintenance Wing – Hill AFB

  • Amie Emerson

    • Spirit Aerosystems

  • John Haddock

    • BAE Systems – MAS

  • Tim Hayes

    • General Dynamics

  • Danieli Hilgemberg

    • Embraer

  • Scott Iby

    • Hamilton Sundstrand

  • Scott Klavon, Secretary (Non-Voting)

    • PRI

  • Ralph Kropp

    • MTU Aero Engines GmbH

  • Peter Krutoholow

    • Sikorsky

  • Serge Labbe

    • Heroux Devtek

  • Daniel Lecuru

    • Eurocopter

  • Eric LeFort

    • Sonaca

  • Howard Jeff Lott

    • The Boeing Company

  • Frank Mariot

    • Vought Aircraft

  • Steve McGinn

    • Honeywell

  • Robin McGuckin

    • Bombardier Aerospace

  • Michael Murray

    • Beechcraft Corporation

  • Colby Nicks

    • Bell Helicopter Textron

  • Ana Ottani dos Santos

    • Embraer

  • Rick Peterson

    • Rockwell Collins, Inc.

  • Alberto Portal

    • EADS – CASA

  • Mark Rechtsteiner

    • GE Aviation

  • Per Rehndell

    • Volvo Aero Corporation

  • Brad Richwine

    • Raytheon Company

  • Davide Salerno

    • Alenia Aeronautica SpA

  • Victor Schonberger

    • IAI

  • Lisa Shaw

    • Eaton Aerospace

  • Henry Sikorski

    • Pratt & Whitney

  • Asa Snitchler

    • Beechcraft Corporation

  • Kevin Ward, Vice Chairperson

    Goodrich Corporation

  • Kirk Whalen

    Heroux Devtek

  • George Winchester

    Northrup Grumman

  • Corwyn Berger

    EXOVA, Inc.

  • Michael Brandt

    Alcoa

  • Mark Brown

    Kaman Aerospace Group

  • Tim Crowe

    Dearborn Precision

  • Robert Custer

    AAA Plating & Inspection

  • Suzanna DeMoss

    Advanced Chemistry & Technology

  • Eric Jacklin

    FM Callahan & Son

  • David Jones

    Nex-Tech Processing.

  • David Michaud

    Fountain Plating Company

  • Michael Schleckman

    Voss Industries, Inc.

  • Vitorio Stana

    Avcorp Industries Inc

  • Vern Talmadge

    Howmet Thermatech Coatings


Pri nadcap organizational structure2

PRI/Nadcap ORGANIZATIONAL STRUCTURE

Policy

Board of Directors

AdministrativeStaff

Nadcap Management Council (NMC)

Tactical

Task Groups

Special Processes

Nondestructive Testing,

Materials Testing,

Heat Treating, Coatings,

Chemical Processing,

Welding, NMSE, Non Metallic Materials Testing & Conventional Machining

Systems & Products

Electronics,

Sealants, Elastomer Seals,

AQS (AC7004),

Fluid Distribution Systems &

Composites

Supplier Support Committee (SSC)

Technical

  • Technical Experts

  • Determine requirements

  • Develop documents

  • Accept corrective action

  • Final decision on accreditation


Agenda2

AGENDA

  • Nadcap Overview

  • Organizational Structure of Nadcap

  • Nadcap Process / eAuditNet


Nadcap procedure hierarchy

Nadcap PROCEDURE HIERARCHY

Aerospace Standard which documents the requirements for implementing Nadcap industry consensus-based accreditation programs.

AS7003

Quality policy describing the quality system of the organization.

QUALITY MANUAL

NOP (Nadcap Operating

Procedure)

Specific procedures by which Nadcap operates.

Scope and general operating procedures for each specific Nadcap commodity program.

NTGOP (Nadcap Task Group Operating Procedure)

NIP (Nadcap Internal Procedure)

Specific procedures by which PRI / Nadcap Staff operates.

Roles and responsibilities for Nadcap Auditors, and clarifications to facilitate and standardize the audit process.

Auditor Handbook


Key procedures located on eauditnet under nadcap procedures

KEY PROCEDURES (Located on eAuditNet, under Nadcap Procedures)

  • NOP-001: Nadcap Operating Procedure

  • NOP-006: Supplier Advisory Process

  • NOP-008: Supplier Merit Program

  • NOP-011: Audit Failure Process

  • NTGOP-001: Nadcap Task Group Operating Procedure


The nadcap audit process

THE Nadcap AUDIT PROCESS

Subscriber Action

Supplier Action

PRI Action

Accreditation Mandated by Nadcap Prime Subscriber

Supplier Requests

Audit

Audit Scheduled

& Auditor Assigned

Audit Performed

– Auditor Submits

Report

Re-accreditation Process

Supplier

Review

Certificate Issued

to Supplier

Task Group

Review

PRI Technical

Staff Review


Audit process

AUDIT PROCESS

  • PRI/Supplier Schedules the Audit using eAuditNet.com

    • Nadcap Checklists and Preparation Instructions available

    • Encouraged to review the Nadcap Customer Support Initiative (NCSI) presentation on eAuditNet

    • Perform self-audit

  • Auditor Conducts the Audit using the applicable Nadcap checklists (located on eAuditNet)

    • Daily briefing & a final close out meeting at the end of the audit

  • Auditor Prepares Cover Letter and attaches to audit report (uploaded into eAuditNet)

  • Supplier has 21 calendar days to initially respond to any findings (7 calendar days for subsequent responses)


Every step is managed by industry

EVERY STEP IS MANAGED BY INDUSTRY

AUDIT CHECKLIST

PROCESS EVALUTION/ IMPROVEMENT

AUDITOR QUALIFICATION & SELECTION

INDUSTRY EXPERTS MANAGE ALL KEY STEPS

CORRECTIVE ACTIONS AS REQUIRED

AUDIT CONDUCTED

AUDIT RESULTS


Nadcap industry working together

Nadcap – INDUSTRY WORKING TOGETHER

Task Groups

(Primes)

Nadcap Staff

Suppliers

Establish Audit Criteria

Audit Criteria (AC):

Document containing checklists or other surveillance tools to be utilized in the course of determining compliance to established industry standards and prime requirements.


Relationship between audit criteria ac audit handbook and prime requirements

RELATIONSHIP BETWEEN AUDIT CRITERIA (AC), AUDIT HANDBOOK AND PRIME REQUIREMENTS

AC7XXXAudit CriteriaJob Audits

AuditHandbook

Industry

Standards

+

Prime

Requirements


Industry managed program

INDUSTRY MANAGED PROGRAM

AUDIT CHECKLIST

PROCESS EVALUTION/ IMPROVEMENT

AUDITOR QUALIFICATION & SELECTION

INDUSTRY EXPERTS MANAGE ALL KEY STEPS

CORRECTIVE ACTIONS AS REQUIRED

AUDIT CONDUCTED

AUDIT RESULTS


Audit selection interview performance

AUDIT SELECTION/INTERVIEW/PERFORMANCE

  • Core and Technical Requirements are Established by Task Group

  • Potential candidates complete a pre-screening questionnaire oneAuditStaff.com

  • Interviewed by Task Group

  • Testing/Certification (Optional)

  • Training Audits

  • Review of Training with Report from Lead Auditor

  • Approval by Task Group

  • Continual Monitoring through Audit Reviews

  • Annual PRI/Nadcap Training


Auditors critical to nadcap

AUDITORS CRITICAL TO Nadcap

  • Highly skilled technical background with average of 30 years experience in the Special process audited

  • Unlike ISO or EN 9000 based audits, Nadcap auditors do not make the final decision

  • Nadcap auditor goal is to evaluate and report the technical competency and compliance of the supplier


Sample of current auditors experience

SAMPLE OF CURRENT AUDITORS & EXPERIENCE


Industry managed program1

INDUSTRY MANAGED PROGRAM

AUDIT CHECKLIST

PROCESS EVALUTION/ IMPROVEMENT

AUDITOR QUALIFICATION & SELECTION

INDUSTRY EXPERTS MANAGE ALL KEY STEPS

CORRECTIVE ACTIONS AS REQUIRED

AUDIT CONDUCTED

AUDIT RESULTS


Nadcap audit content

Nadcap AUDIT CONTENT

  • Quality Systems

  • Special Process and Product Specific Requirements

  • Compliance/Job Audits

    NDT: 3 Witnessed Compliance Jobs per Method and 3 “Paperwork” Completed Compliance Jobs per Method

    Heat Treating: 2 Long Jobs-8 Short Jobs

    Materials Lab: Witnessing of All Test Methods

    Chemical Processing: Minimum of 4 Job Audits

    Coatings: 2-11 Job Audits (Based on Scope)

    Welding: 2 Job Audits per Method

    Nonconventional Machining: 2-10 Job Audits

    Surface Enhancement: 2-6 Job Audits

    Composites: 15-30 Job Audits (Based on Manufacturing Flow)

    Electronics: Complete 1 Job Audit

    Conventional Machining: 2-14 Job Audits (Based on Scope)


General focus audit

GENERAL FOCUS AUDIT

Calibration:

Does the supplier define the process employed for the calibration of inspection, measuring and test equipment type, unique identification, location, frequency of checks, check method, acceptance criteria and the action to be taken when results are unsatisfactory?

Chemical Processing

Heat Treating

NDT


Jon steffey program manager informatics solutions research and development 3 june 2013

TECHNICAL (Nadcap) FOCUS AUDIT

Is measuring and test

equipment used to control or monitor the control of a process (within parameters)

maintained in a calibration system compliant with

ISO 10012-1?

(I.e. temperature gages, conductivity meters, voltmeters, rectifiers)

Are furnaces used for

heat treating Aluminum parts surveyed at the

required tolerance and

temperature range?

Are the FPI dryer ovens calibrated every three months at multiple points across the usable range?

Calibration:

Heat Treating

NDT

Chemical Processing


Industry managed program2

INDUSTRY MANAGED PROGRAM

AUDIT CHECKLIST

PROCESS EVALUTION/ IMPROVEMENT

AUDITOR QUALIFICATION & SELECTION

INDUSTRY EXPERTS MANAGE ALL KEY STEPS

CORRECTIVE ACTIONS AS REQUIRED

AUDIT CONDUCTED

AUDIT RESULTS


Ncr classifications

NCR CLASSIFICATIONS

  • Major Nonconformance:

    • The absence of, or systemic breakdown of, the Process Control and/or Quality Management system.

    • Any non-conformance where the effect impacts or has the potential to impact the integrity of the product.

  • Minor Nonconformance:

    • A non-systemic lapse in conformance to the Process Control and/or Quality Management system.


  • Audit review

    AUDIT REVIEW

    PRI Staff Review:

    • Staff Reviews Package for Completeness

    • Review Audit Report

      • Clarification Changes (electronically) - Contact Auditors for Clarification

      • Review Supplier Corrective Action

      • Close-Out or request additional information via Forums

    • Audit Report Package is submitted via eAuditNet for Task Group Review


    Audit review1

    AUDIT REVIEW

    Task Group Review:

    • Task Group decides Procedure for Review

      • Sub-group review, entire Task Group Review

    • Task Group Reviews for Correctness

      • Technical Comments, Supplier Responses, Technical Completeness, Auditor Summary Letter, Identify Additional Findings

    • Completes Review of Each NCR and dispositions (NCR Status)

    • Discuss Results with Task Group within Forums

    • Task Group Votes on Accreditation via On-Line Balloting


    Nadcap industry working together1

    Nadcap – INDUSTRY WORKING TOGETHER

    Task Groups

    (Primes)

    Establish Audit

    Criteria

    Nadcap Staff

    Suppliers

    Interview &

    Recommend Auditor

    Define Auditor

    Requirements

    Perform

    Audit

    Plan/Schedule

    Audits

    Contract Auditor

    Supplier Requests

    Findings

    Submit C/A

    Package

    Review C/A

    Package

    Review &

    Accept C/A

    Accredit Supplier


    Eauditnet for subscribers www eauditnet com

    eAUDITNET FOR SUBSCRIBERS – www.eAuditNet.com

    • Subscribers can use eAuditNet to:

      • Use ‘Subscriber QML’ to specifically search for your company’s suppliers

      • Lookup audit details for a supplier including checklist details, nonconformance (NCR) details, and Supplier and Task Group NCR responses

      • Lookup the current audit status of a supplier

      • Download or print hard copy checklist(s)

      • View new or existing Supplier Advisories

      • View all Nadcap Procedures (NIPs, NOPs, NTGOPs)

    • eAuditNet Company Administrator, you can use eAuditNet to:

      • Create new eAuditNet users for your company

      • Edit current eAuditNet users for your company

      • Accept or reject eAuditNet users that select your company during registration

      • Set-up company Users to receive weekly e-mails regarding your QML supplier audits that were submitted (Email Subscription Application)

    • If you are a Task Group Member, you can use eAuditNet to:

      • View and discuss supplier audit NCRs

      • Ballot on supplier audit and merit recommendations

        An eAuditNet Subscriber’s Audit Review Guide and eAuditNet Company

        Administrator’s Guide can be downloaded from eAuditNet using

        Public Documents.


    Industry managed program3

    INDUSTRY MANAGED PROGRAM

    AUDIT CHECKLIST

    PROCESS EVALUTION/ IMPROVEMENT

    AUDITOR QUALIFICATION & SELECTION

    INDUSTRY EXPERTS MANAGE ALL KEY STEPS

    CORRECTIVE ACTIONS AS REQUIRED

    AUDIT CONDUCTED

    AUDIT RESULTS


    Jon steffey program manager informatics solutions research and development 3 june 2013

    TOP 10 PARAGRAPHS SINCE RELEASE OF COMP AC7118 REV A232 AUDITS


    Ndt top paragraph references ac7114 sample 2010

    NDT TOP PARAGRAPH REFERENCES AC7114 (SAMPLE – 2010)


    Quality improvements for suppliers ssc 2009 survey results

    QUALITY IMPROVEMENTS FOR SUPPLIERS (SSC 2009 SURVEY RESULTS)

    An increasing percentage of Nadcap accredited companies report quality improvement in the area(s) related to their Nadcap accreditation(s).


    Jon steffey program manager informatics solutions research and development 3 june 2013

    • Supplement with PRI Responsible for the ‘process’

    • Industry Standards

    • Procedures

    • Oversight

    • Core Values

    User/Primes

    “LIABILITY”

    Does not shift

    Supplier

    Conformity

    Central Information Network

    “eAuditNet”

    • Agreements:

    • Auditors

    • Suppliers

    • Users

    PRI/Nadcap

    Early Warnings

    Nadcap-Wide

    Reduce Risk

    Reduce Escapes

    Supplier Responsiveness

    Consistency in Training


    Next nadcap meeting

    NEXT Nadcap MEETING

    21-25 October 2013

    Pittsburgh, PA USA

    On-line registration available at

    www.pri-network.org

    Reservation information will be posted on the

    PRI website (www.pri-network.org) when available.


    Questions

    QUESTIONS

    QUESTION TIME

    ?


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