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Nadcap SUPPLIER TUTORIAL Thomas Newton Aircraft X-Ray Laboratories Supplier Support Committee Leadership Team Chair Paul Evans James Fisher Nuclear Limited Supplier Support Committee Leadership Team Lisa Jensen-Donahoe Alcoa Supplier Support Committee Mentoring Sub-Team Lead 24 June 2014
Nadcap SUPPLIER TUTORIAL PURPOSE OF THIS SESSION 2 • Provide some background on Nadcap. • Show you where to find the information and tools to successfully prepare for your Nadcap audit. • Introduce you to key individuals who can help you understand the Nadcap accreditation process.
Nadcap SUPPLIER TUTORIAL INTRODUCE YOURSELF 3 • Your name • Company name • What special process or processes will be audited?
Nadcap SUPPLIER TUTORIAL INTRODUCING THE SUPPLIER SUPPORT COMMITTEE (SSC) MISSION STATEMENT Our goal is to represent the supplier community and work with the Nadcap Management Council to enhance the effectiveness and economical value of the Nadcap system for the mutual benefit of suppliers and subscribers. 4
Nadcap SUPPLIER TUTORIAL SOME SSC ACHIEVEMENTS WANT TO GET INVOLED? 5 • Supplier Survey every two years • Flowdown templates • Increased Supplier Voting in Task Group ballots • Mentoring program for new suppliers Talk to any SCC member at this meeting
Nadcap SUPPLIER TUTORIAL WHERE DOES THE SSC FIT INTO Nadcap? INDUSTRY REPRESENTATIVES 6 PRI BOARD OF DIRECTORS Nadcap MANAGEMENT COUNCIL TASK GROUPS • TECHNICAL EXPERTS • DETERMINE REQUIREMENTS • FINAL DECISION ON ACCREDITATION POLICY & FINANCIAL OVERSEE Nadcap PROGRAM SUPPLIER SUPPORT COMMITTEE (SSC) • NON-TECHNICAL GROUP • WORK ON SYSTEMIC ISSUES
SUPPLIER SUPPORT COMMITTEE LEADERSHIP TEAM STRUCTURE OF THE SSC LEADERSHIP TEAM CHAIR THOMAS NEWTON Aircraft Xray Laboratories, Inc. 7 SECRETARY JONATHAN HEBBEN Ducommun AMERICAS LLOYD BARKER Alcoa PAST CHAIR ADVISOR ERIC JACKLIN F. M. Callahan & Son VICE CHAIR DALE HARMON Cincinnati Thermal Spray AMERICAS DAVID MICHAUD Fountain Plating TALK TO US ABOUT NON-TECHNICAL ISSUES AMERICAS JIM RINGER Tech Met EUROPE PAUL EVANS JFIMS ASIA LEI BAO China Iron & Steel Research Institute Group
SUPPLIER SUPPORT COMMITTEE TASK GROUP REPRESENTATIVES WE WILL HELP YOU WITH ANY TASK GROUP QUESTIONS Chemical Processing DAVID MICHAUD Fountain Plating Coatings DALE HARMON Cincinnati Thermal Spray Elastomer Seals JOHN HUDSPETH International Seal NDT GARY WHITE Orbit Industries Electronics DOUG SCHUELLER Abel. Conn LLC NMSE DAVE JONES 3 P Processing Inc. Composites VITORIO STANA Avcorp Conventional Machining as a Special Process TIM CROWE Hunting Dearborn, Inc. 8 Heat Treating ROY ADKINS Braddock Metallurgical Materials Testing BRYAN HALL NSL Analytical Services, Inc. Welding MIKE SCHLECKMAN Voss Industries
Nadcap SUPPLIER TUTORIAL AGENDA 9 u Introducing Nadcap • Why Nadcap? • How do I get started? • Audit Preparation Tips • The End of the Audit • What Now?
Nadcap SUPPLIER TUTORIAL Nadcap DEFINITION 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. 10
Nadcap SUPPLIER TUTORIAL ACTIVITY IS GOVERNED BY PROCEDURES AS 7003 Quality policy describing the quality system of the organization. QUALITY MANUAL NOP Nadcap Operating Procedure Scope and general operating procedures for each specific Nadcap commodity program. Specific procedures by which Nadcap operates. NTGOP Nadcap Task Group Operating Procedure NIP Nadcap Internal Procedure Roles and responsibilities for Nadcap Auditors, and clarifications to facilitate and standardize the audit 11 process. Aerospace Standard which documents the requirements for implementing Nadcap industry consensus-based accreditation programs. Auditor Handbook Specific procedures by which PRI / Nadcap Staff operates.
Nadcap SUPPLIER TUTORIAL EVERY STEP IS MANAGED BY INDUSTRY AUDIT CHECKLIST AUDITOR QUALIFICATION & SELECTION PROCESS EVALUTION/ IMPROVEMENT INDUSTRY EXPERTS MANAGE ALL KEY STEPS CORRECTIVE ACTIONS AS REQUIRED AUDIT CONDUCTED AUDIT RESULTS 12
Nadcap SUPPLIER TUTORIAL On Site Audits INDUSTRY-MANAGED ACTIVE CUSTOMER AUDITS Actual results 13
Nadcap SUPPLIER TUTORIAL AGENDA • Introducing Nadcap u Why Nadcap • How do I get started? • Audit Preparation Tips • The End of the Audit • What Now? 14
Nadcap SUPPLIER TUTORIAL WHY Nadcap? • 15 The Customer Perspective – Achieve greater consistency across the supply chain and throughout the industry.
Nadcap SUPPLIER TUTORIAL Nadcap Subscribers • • • • • 16 309 th Maintenance Wing-Hill AFB Agusta. Westland Airbus Group – Aerolia – Airbus Defence & Space – Airbus Helicopters – Premium Aerotech Alenia Aermacchi Sp. A BAE Systems – Military Air Solutions (MAS) BAE Systems Ball Aerospace & Technology Corporation The Boeing Company Bombardier Inc. COMAC Defense Contract Management Agency (DCMA) Eaton Aerospace Embraer GE Aviation – GE Avio S. r. l. General Dynamics – Gulfstream GKN Aerospace Sweden AB Heroux Devtek Inc. (Landing Gear Division) Honeywell Aerospace Israel Aircraft Industries • • • • • Latecoere Liebherr-Aerospace SAS Lockheed Martin Corporation Mitsubishi Aircraft Corporation/Mitsubishi Heavy Industries, LTD MTU Aero Engines AG Northrop Grumman Corporation Parker Aerospace Group Raytheon Company Rockwell Collins, Inc. Rolls-Royce SAFRAN Group Sonaca Spirit Aero. Systems Textron Inc. – Beechcraft Corporation – Bell Helicopter – Cessna Aircraft Company – Textron Systems Thales Triumph Group Inc. United Technologies Corporation – Goodrich (UTAS) – Hamilton Sundstrand (UTAS) – Pratt & Whitney Canada – Sikorsky Aircraft
Nadcap SUPPLIER TUTORIAL WHY Nadcap? • 17 The Supplier Perspective – Because my customer said so!
Nadcap SUPPLIER TUTORIAL THE REAL REASON • Quality Improvements – An increasing percentage of Nadcap accredited companies report quality improvement in the area(s) related to their Nadcap accreditation(s) 83% 77% 25% 18 76% 85%
Nadcap SUPPLIER TUTORIAL AGENDA • Introducing Nadcap • Why Nadcap? u How do I get started? • Audit Preparation Tips • The End of the Audit • What Now? 19
Nadcap SUPPLIER TUTORIAL OBTAIN AND READ THE PRIMARY DOCUMENTS Audit Checklist AC 7 XXX Audit Criteria + Job Audits Industry Standards & Customer Requirements You will be audited using this checklist: get it from e. Audit. Net Audit Handbook Clarifies the checklist & customer requirements: get it from e. Audit. Net 20
Nadcap SUPPLIER TUTORIAL THE Nadcap AUDIT PROCESS Subscriber Action Accreditation Mandated by Nadcap Prime Subscriber Supplier Requests Audit Supplier Action PRI Action Audit Scheduled & Auditor Assigned Audit Performed – Auditor Submits Report Re-accreditation Process Supplier Review Certificate Issued to Supplier 21 Task Group Review PRI Technical Staff Review
Nadcap SUPPLIER TUTORIAL SCHEDULE THE AUDIT 22 • Complete a preliminary questionnaire and return it to PRI Scheduling Staff • PRI Scheduling Staff will send you a quote for the audit cost and duration • Schedule the audit using e. Audit. Net (and help from PRI Scheduling if needed) for a time that suits you (and meets your customers expectations)
Nadcap SUPPLIER TUTORIAL DO SOME RESEARCH, GO TO www. e. Audit. Net. com 1. Register as a new user (limited access) 2. Contact PRI for full access (email e. Audit. Net. [email protected] org) 23 e. Audit. Net Tutorial immediately after this session
Nadcap SUPPLIER TUTORIAL IMPORTANT! AUDIT SCHEDULING • Schedule the audit when you are processing real parts from an aerospace customer • The auditor wants to see job audits (a step-by-step review of all processing on actual hardware to evaluate how you meet customer requirements) • Tell PRI in advance if you will not have real parts for the Nadcap audit 24
Nadcap SUPPLIER TUTORIAL AGENDA • Introducing Nadcap • Why Nadcap? • How do I get started? u Audit Preparation Tips • The End of the Audit • What Now? 25
Nadcap SUPPLIER TUTORIAL READ THE PROCEDURES • NIP 7 -02 Audit Process • NIP 7 -04 Post-Audit Process • NIP 7 -07 Export controlled Materials & Information • NOP-008 Supplier Merit Program • NOP-011 Audit Failure Process 26 Available on e. Audit. Net Why does this matter? The procedures provide guidance on key aspects of the process including: • Response timeframes • How to reduce audit frequency from 12 to 24 months • How NOT to fail the audit and what happens if you do
Nadcap SUPPLIER TUTORIAL UNDERSTAND THE NCR CLASSIFICATIONS Major Non-conformance: • 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. Minor Non-conformance: • Any single system failure or lapse in conformance with the applicable standard or audit criteria 27
Nadcap SUPPLIER TUTORIAL CHECK YOUR QUALITY SYSTEM APPROVAL Nadcap recognizes: • AS / EN / JISQ 9100 and AS 9003 – From a registrar listed in the l. AQG OASIS database – Substitute: AC 7004 • l. SO / l. EC 17025 – For testing laboratories – From a NACLA/l. LAC approved accreditation body – Substitute: AC 7006 28
Nadcap SUPPLIER TUTORIAL EVIDENCE YOUR QUALITY SYSTEM APPROVAL For initial audits: • Provide a copy to PRI Scheduling when you schedule your Nadcap audit • If you don’t have this, AC 7004 / AC 7006 will be added to the scope For reaccreditation audits • Provide a copy up to 60 days after the audit end date OR • Schedule AC 7004 / AC 7006 at least 90 days before the audit start date (if you know you won’t comply with option 1) 29
Nadcap SUPPLIER TUTORIAL PERFORM A SELF AUDIT! Use the Nadcap checklist • Be strict with yourself • For each question, record: – Where in your system you meet the requirement – Where you have objective evidence of compliance 30
Nadcap SUPPLIER TUTORIAL USE THE SELF AUDIT RESULTS TO IMPROVE YOUR OPERATIONS • If you cannot list where in your system you have documentation and what you will show the auditor the answer is NO! • Fix all ‘No’s with Root Cause Corrective Action before the Nadcap auditor arrives 31
Nadcap SUPPLIER TUTORIAL AGENDA • Introducing Nadcap • Why Nadcap? • How do I get started? • Audit Preparation Tips u The End of the Audit • What Now? 32
Nadcap SUPPLIER TUTORIAL AT THE END OF THE AUDIT • Meet the auditor to review the report including any non-conformances (NCRs) • Ensure all NCRs are understood: this is what you are responding to. If it’s not clear to you, will the Staff Engineer / Task Group understand? • Invite the right people including top management • Raise any issues or problems 33 Meet with the auditor each day for a review so there are no surprises
Nadcap SUPPLIER TUTORIAL AFTER THE AUDITOR LEAVES • Provide feedback about the audit on e. Audit. Net • Appeal an NCR, Staff Engineer decision or Task Group decision if you are not happy – Contact the Staff Engineer for information • Contact PRI Management if you’re not satisfied Scott Klavon Director Nadcap program and Aerospace Operations +1 -724 -772 -7111 [email protected] org 34 Meet wih each day for a review so there are no surprises
Nadcap SUPPLIER TUTORIAL RESPOND TO ALL NON-CONFORMANCES Provide the following in your answer: • Immediate Corrective Action Taken (Containment) • Root Cause of Non-conformance • Impact of all Identified Causes and the Root Cause • Action Taken to Prevent Recurrence • Objective Evidence Attached 35
Nadcap SUPPLIER TUTORIAL RESPONSE DUE DATES • Initial responses: 21 calendar days • Subsequent responses: 7 calendar days • Important note: This is the time to respond to the NCRs, not necessarily to fix them • No extensions can be granted BUT • 30 extra days are allocated in case more time is needed • Be aware: using extra days may affect merit and using more than 30 extra days may result in audit failure 36
Nadcap SUPPLIER TUTORIAL NEED MORE HELP WITH RCCA? • www. eauditnet. com A link to Response Requirements is on the page with the NCR • www. equalearn. com Root Cause Corrective Action training class • www. pri-network. org Free whitepaper called Root Cause Corrective Action – Nadcap Style (in the News section) 37
Nadcap SUPPLIER TUTORIAL FREE TRAINING AT Nadcap MEETINGS • Throughout 2014, PRI is offering free e. Qua. Learn training classes at Nadcap meetings. • Due to the popularity of these sessions, places are allocated on a first-come, first-serve basis. • To date, topics have included: • Root Cause Corrective Action • Introduction to Pyrometry • How to Prepare for a Nadcap Audit • Internal Auditing • Learn more and register at www. equalearn. com. 38
Nadcap SUPPLIER TUTORIAL AGENDA • Introducing Nadcap • Why Nadcap? • How do I get started? • Audit Preparation Tips • The End of the Audit u What now? 39
Nadcap SUPPLIER TUTORIAL REMEMBER THE KEY POINTS • Do your research • Be prepared • Perform a self-audit • Understand Root Cause Corrective Action • 40 Ask for help if you need it!
Nadcap SUPPLIER TUTORIAL MAKE CONTACT • PRI Scheduling Staff • Nadcap Staff Engineers • Supplier Support Committee To get involved, request a mentor, etc • e. Qua. Learn For training on RCCA etc 41 To arrange your audit For guidance on checklist interpretation
Nadcap SUPPLIER TUTORIAL MENTORING PROGRAM If you would like to request a mentor, please send an email to Nadcap. [email protected] org • Objective • To provide names and contact information of experienced Nadcap suppliers (Mentors) to suppliers (Mentees’) new to the process or in need of assistance navigating the Nadcap system. • Benefits • Gain an understanding of the Nadcap process by working with a passionate Mentor who has extensive process and value-added experience • Open communication with an accredited supplier who can provide insight into the Nadcap program • Collaboration with Task Groups • Link Suppliers with SSC and Nadcap resources 42
Nadcap SUPPLIER TUTORIAL GO ONLINE • www. p-r-i. org - • www. e. Audit. Net. com - Nadcap audit specific website • www. e. Qua. Learn. com - 43 PRI company website PRI training opportunities
Nadcap SUPPLIER TUTORIAL ANY QUESTIONS? To receive a copy of this presentation, email Nadcap. [email protected] org Thank you for your participation Please ask questions and give feedback on this tutorial 44