PRI-SSC-Tutorial - Performance Review Institute

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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
INDUSTRY REPRESENTATIVES
WHERE DOES THE SSC FIT INTO Nadcap?
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.
AMERICAS
LLOYD BARKER
Alcoa
VICE CHAIR
DALE HARMON
Cincinnati Thermal
Spray
7
TALK TO US ABOUT
NON-TECHNICAL ISSUES
SECRETARY
JONATHAN HEBBEN
Ducommun
AMERICAS
JIM RINGER
Tech Met
PAST CHAIR ADVISOR
ERIC JACKLIN
F. M. Callahan & Son
EUROPE
PAUL EVANS
JFIMS
AMERICAS
DAVID MICHAUD
Fountain Plating
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
AbelConn LLC
NMSE
DAVE JONES
3P 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

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
AS7003
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
INDUSTRY-MANAGED ACTIVE CUSTOMER AUDITS
6000
On Site Audits
5000
4000
3000
2000
1000
0
2002
2003
2004
2005
2006
2007
2008
Actual results
13
2009
2010
2011
2012
2013
2014
Plan
Nadcap SUPPLIER TUTORIAL
AGENDA
•
Introducing Nadcap

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
309th Maintenance Wing-Hill AFB
AgustaWestland
Airbus Group
–
Aerolia
–
Airbus
–
Airbus Defence & Space
–
Airbus Helicopters
–
Premium Aerotech
Alenia Aermacchi SpA
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
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 AeroSystems
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
–
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
100
•
Quality Improvements
– An increasing percentage of
Nadcap accredited
companies report quality
improvement in the area(s)
related to their Nadcap
accreditation(s)
80
60
83%
77%
76%
2005
2007
85%
40
20
25%
0
2003
18
2009
2011
Nadcap SUPPLIER TUTORIAL
AGENDA
•
Introducing Nadcap
•
Why Nadcap?

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
AC7XXX
Audit Criteria
+
Job Audits
Industry Standards &
Customer
Requirements
You will be audited using this
checklist: get it from eAuditNet
Audit
Handbook
Audit
Handbook
Clarifies the checklist & customer
requirements: get it from
eAuditNet
20
Nadcap SUPPLIER TUTORIAL
THE Nadcap AUDIT PROCESS
Subscriber Action
Supplier Action
Accreditation
Mandated by
Nadcap Prime
Subscriber
Supplier Requests
Audit
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 eAuditNet
(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.eAuditNet.com
1.
1. Register as a new user (limited access)
2. Contact PRI for full access (email eAuditNetSupport@p-r-i.org)
23
eAuditNet 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?

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
eAuditNet
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:
•
27
Any single system failure or lapse in conformance with the
applicable standard or audit criteria
Nadcap SUPPLIER TUTORIAL
CHECK YOUR QUALITY SYSTEM APPROVAL
Nadcap recognizes:
•
AS / EN / JISQ 9100 and AS9003
– From a registrar listed in the
lAQG OASIS database
– Substitute: AC7004
•
lSO / lEC 17025
– For testing laboratories
– From a NACLA/lLAC approved
accreditation body
– Substitute: AC7006
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, AC7004 / AC7006 will be added to
the scope
For reaccreditation audits
• Provide a copy up to 60 days after the audit end date OR
• Schedule AC7004 / AC7006 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

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 eAuditNet
•
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
sklavon@p-r-i.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.p-r-i.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 eQuaLearn
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

What now?
39
Nadcap SUPPLIER TUTORIAL
REMEMBER THE KEY POINTS
•
Do your research
•
Be prepared
•
Perform a self-audit
•
Understand Root Cause
Corrective Action
•
Ask for help if you need it!
40
Nadcap SUPPLIER TUTORIAL
MAKE CONTACT
•
PRI Scheduling Staff
To arrange your audit
•
Nadcap Staff Engineers
For guidance on checklist
interpretation
•
Supplier Support Committee
To get involved, request a
mentor, etc
•
eQuaLearn
For training on RCCA etc
41
Nadcap SUPPLIER TUTORIAL
MENTORING PROGRAM
If you would like to request a
mentor, please send an email to
NadcapSSC@sae.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.eAuditNet.com - Nadcap audit specific website
•
www.eQuaLearn.com -PRI training opportunities
43
PRI company website
Nadcap SUPPLIER TUTORIAL
ANY QUESTIONS?
To receive a copy of this presentation, email
NadcapSSC@sae.org
Thank you for your participation
Please ask questions and give feedback
on this tutorial
44
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