WELDING OCTOBER 2014 CONFIRMED CONFIRMED MINUTES OCTOBER 20-22, 2014 PITTSBURGH, PENNSYLVANIA, USA These minutes are not final until confirmed by the Task Group in writing or by vote at a subsequent meeting. Information herein does not constitute a communication or recommendation from the Task Group and shall not be considered as such by any agency. MONDAY, 20-OCT-2014 to WEDNESDAY, 22-OCT-2014 1.0 OPENING COMMENTS 1.1 Call to Order / Quorum Check The Welding (WLD) Task Group was called to order at 8:00 a.m., 20-Oct-2014 by Steve Tooley. Introductions were made and the roster circulated for completion by attendees. It was verified that only SUBSCRIBER MEMBERS were in attendance during the closed portion of the meeting. A quorum was established with the following representatives in attendance: Subscriber Members/Participants Present (* Indicates Voting Member) NAME * * * * * * * * * * * * * * * * * * COMPANY NAME Robbie Osawonuyi Christopher Julian Saeed Gary Bill Bob Adams Agbonkonkon Borg Buckland Cheema Coleman Fitzgerald Fletcher Jenny Larry Milan Brian Hirohiko Les Rodney Jerry Michael Jerry Ralph Holger Mario Don Scott Jason Tim Earl Joe Brittney Brian Joe Fullum Hamanishi Hanyk Harvey Hattori Hellemann Holt Hulin Irvin Isoaho Kropp Krueger Leclerc Lenhart Maitland Merrell Nance Pruett Reigle Reid Ricks Sebastiani Honeywell Aerospace Parker Aerospace Group Gulfstream Aerospace Corp. SAFRAN Group Textron Inc. The Boeing Company Northrop Grumman Corporation BAE Systems- Military Air & Information (MAI) Parker Aerospace Group The Boeing Company Honeywell Aerospace Gulfstream Aerospace Corporation Mitsubishi Heavy Industries (MITAC/MHI) GE Aviation Triumph Group Inc. GKN Aerospace The Boeing Company GKN Aerospace Sweden AB MTU Aero Engines AG Airbus Bombardier Spirit AeroSystems Goodrich (UTAS) U.S. Air Force Rockwell Collins Inc. Lockheed Martin Corporation Parker Aerospace Group Parker Aerospace Group Raytheon Company Defense Contract Management Agency Secretary Vice Chairperson WELDING OCTOBER 2014 CONFIRMED * Paul Naoki Len Steve Kimberly Slater Sogabe Tidwell Tooley Woodside Rockwell Collins, Inc. Mitsubishi Heavy Industries (MITAC/MHI) Lockheed Martin Corporation Rolls-Royce Parker Aerospace Group Chairperson Other Members/Participants Present (* Indicates Voting Member) NAME * * * * * * * * * James Christy Michael Aja Richard Jim Darron Dan Andrew David Richard Shelly Steve Melinda Angelo Julie Jim David T. J Chris Mike Jackie Gigi Kevin Christopher COMPANY NAME Ahlemeyer Ballinger Chmura Collins Freeman Harlukowicz Harris Isherwood Jackson Jones Kline Lawless McGinns Mitton Monzo Motz Olejarczyk Osenar Owen Reed Schleckman Sternot Streeter Vecchiarelli Webb Ducommun AeroStructures Ducommun Litron Inc. Unison Engine Components TWI Ltd. Wyman Gordon Exotic Metals Forming Company Yankee Casting AMPP Services Ltd. Precision Protective Coatings X-Ray Industries Meyer Tool, Inc. PCC Airfoils Advance Welding Barnes Aerospace Barnes Aerospace Alcoa Forged Products PAKO, Inc. Geater Machining & Manufacturing Co. Ducommun Voss Industries PAKO, Inc. Barnes Aerospace Yankee Casting Co., Inc. PCC Structurals Inc. PRI Staff Present Rhonda Joanna Justin Stacey Kellie Ian 1.2 Joseph Leigh McCabe McKinley Roach Simpson Review Code of Ethics (Ref: Attendees’ Guide) and Meeting Conduct The Code of Ethics and Meeting Conduct policies were reviewed. 1.3 Present the Antitrust Video The Antitrust policy video was shown. 1.4 Review Agenda Ian Simpson reviewed the agenda for the October 2014 Nadcap meeting. New business items were identified for inclusion in item 7.0 (in closed meeting) and item 16.0 (in open meeting). Mario WELDING OCTOBER 2014 CONFIRMED Leclerc volunteered to be the Secretary on Wednesday, 22-Oct-2014 in the absence of Les Hellemann. 1.5 Approval of Previous Meeting Minutes– OPEN Motion made by Gary Coleman and seconded by Mike Schleckman to accept the June 2014 Nadcap meeting minutes from Dublin, Ireland as written. Motion passed. 1.6 RAIL Review – OPEN The Rolling Action Item List (RAIL) was reviewed by Ian Simpson. All items with a due date of October 2014 or prior are either closed or are included in this meeting for discussion. For specific details, please see the current WLD Rolling Action Item List posted at www.eAuditNet.com, under Public Documents. 1.7 Staff Engineer Communiqué Ian Simpson presented a Nadcap Communiqué to the Task Group. 1.7.1 Revisions to Nadcap Operating Procedure NOP-001 (Membership definition, membership maintenance, Verification Corrective Action audit process, appeal process clarified, addition of time intervals appendix); General Task Group Procedure NOP-002 (allowance for Supplemental criteria to be incorporated in main checklist); Oversight NOP-004 (Scope of Oversight plan, frequency of reporting results); Supplier Advisories NOP-006 (Advisory retraction). 1.7.2 The March 2015 Nadcap meeting will be held in Berlin, Germany. 1.8 Steve Tooley presented his expectations for meeting conduct. 2.0 AUDITOR CONFERENCE – CLOSED The Auditor Conference was conducted at the weekend prior to this meeting, October 18-19, 2014. The Task Group analyzed the effectiveness of the Auditor Conference and in general the Task Group members who attended stated that it had been positive. Items that were particularly well received were the Audit Professionalism, the Visual weld inspection presentation and the Subscriber witnessed issues post Nadcap audit. Items that could be improved were encouragement for all auditors to participate and conversely limit the discussion of some. The Task Group stated that they would also like to review the auditor’s feedback to establish areas that they felt were beneficial and those that could be improved. This information will be collected by Performance Review Institute (PRI) and can be reviewed at the March 2015 meeting. Based on this review, items identified by the auditors, previously identified training items and the review of Auditor Consistency per NOP-012, the following recommendations were made for next year’s conference. Subscriber specific training from Textron and Pratt & Whitney Smart checklist – feedback from 2-3 Auditors on how the system is working Nonconformance Report (NCR) writing re-fresher Best / worst audit experience from each auditor Update on professionalism Supplier Feedback Specification update Opportunity for feedback on checklists General Question and Answer WELDING OCTOBER 2014 CONFIRMED It was also noted that the expectation of NOP-012 is that face-to-face meetings with auditors will occur in 2015 to give them annual feedback. This will require the support of Subscribers to give this feedback. This item is was discussed further; see item 3.1.1 ACTION ITEM: Ian Simpson to draft the 2015 Auditor Conference based on the suggested training items. (Due Date: 3-Mar-2015) 3.0 AUDITOR EFFECTIVENESS – CLOSED 3.1 Review of NOP-012 Ian Simpson reviewed NOP-012, Auditor Consistency procedure and milestone plan provided by the NOP-012 Implementation Team. In general, the Task Group is on track to meet the NOP-012 deliverables as defined on the milestone plan. The following items were discussed: 3.1.1 Annual Review of Auditors Annual Auditor feedback mechanism. This item has been discussed in detail at the prior 3 Task Group meetings. Initially the Task Group believed that the per audit review was sufficient to negate any further action. This was however challenged by the NOP-012 Implementation team. At the June 2014 Nadcap Meeting the Task Group agreed that they would summarize each individual auditor’s evaluation compared to the average commodity scores. The Nadcap Management Council (NMC) implementation team again challenged the Task Group that this did not meet their expectations. Steve Tooley and Ian Simpson were therefore actioned to propose further additions and seek NMC acceptance. Hence, a template for annual review was created that includes audit score, supplier feedback comments, observation audit results and recommendations. This template was agreed by the NMC Implementation Team and was reviewed by the Task Group. The Task Group agreed to use this template and the Staff Engineer actioned to complete an annual review for each auditor. It was noted, where possible, that the report should include any positive feedback, as well as any opportunities for improvement. It should be noted that due to the time taken to finalize a method that was agreeable to the NMC, this item will not be completed by October 2014 and is now planned to be complete by December 2014. The discussion that Steve Tooley and Ian Simpson had with the NMC on the annual auditor feedback, also defined the feedback mechanism. Due to the delay in agreement of this item, it is logistically impossible to have face-to-face discussions with the auditors in 2014. Hence for 2014, the NMC agreed that for those auditors with no issues, it would be acceptable to e-mail the evaluation, giving them an opportunity to discuss if desired. For those auditors that the Task Group have noted issues, it was decided that at least a telephone discussion with the Staff Engineer is required. Beyond 2014, it would be desirable to have face-to-face discussions with each auditor. This would require the support of Task Group Subscriber members at the Auditor Conference. There was some discussion on how this should be accomplished and Steve Tooley stated he would request further guidance at the NOP-012 Roundtable meeting. This was duly completed and the minimum that would be acceptable would be to have face-to-face meetings with any auditor who has issues. The NMC would however prefer for all auditors to be addressed in faceto-face meetings from 2015. The Task Group will need to further evaluate the logistics of how these meetings will be conducted in 2015 and beyond. WELDING OCTOBER 2014 CONFIRMED ACTION ITEM: Ian Simpson to create an annual auditor review chart for each auditor. Steve Tooley to be consulted if deemed necessary by Ian Simpson during their creation. (Due Date: 30-Nov2014) ACTION ITEM: Ian Simpson to provide each auditor with an annual report and discuss with individuals as deemed necessary. (Due Date: 31-Dec-2014) 3.1.2 Open Communication Plan This was also an outstanding item post the June 2014 Nadcap Meeting. At the meeting Steve Tooley and Ian Simpson had with the NMC, the method utilized by the WLD Task Group was discussed and agreed. i.e. No internet forum discussion group, instead using the Staff Engineers as a single point of contact for general and checklist issues Subscriber Task Group representatives can be contacted for Subscriber specific questions either directly or via the Staff Engineer Suggestion for checklist content / revisions can be provided to the Staff Engineer directly at any time, in response to the annual review or at the Auditor Conference The NMC agreed that this was sufficient to meet the Open Communication requirements imposed by NOP-012. The auditors were reminded that they have these options at the October 2014 Auditor Conference. 3.1.3 Supplier feedback data review It was noted at the June 2014 Nadcap Meeting that the next 6 months of data would be available prior to this meeting. In order to ensure the Auditor Conference included the most recent information, Steve Tooley and Ian Simpson were actioned to review the data and include any generic items in the Auditor Conference. This was completed. The summary was however reviewed by the Task Group to establish if any specific items were required. The Task Group agreed that the generic training on the vast majority of items was sufficient at this time, however, also noted that some specific feedback was required for a few of the auditors and that this should be included on their Annual Feedback forms. ACTION ITEM: Ian Simpson to include auditor specific items as a result of supplier feedback comments to relevant Auditor’s Annual feedback forms. (Due Date: 30-Nov-2014) It was also noted that the existing form that is used to show daily debriefs have occurred could be modified to show attendees of the opening meeting. The Task Group felt that this would be beneficial to provide evidence that the opening meeting had occurred, should there ever be a dispute after the audit. ACTION ITEM: Ian Simpson to modify the existing daily debrief log to add an entry for the opening meeting. (Due Date: 31-Dec-2014) The next 6 months of data will be available for analysis prior to the March 2015 meeting. Steve Tooley and Ian Simpson volunteered to analyze this and provide a summary at the March 2015 Nadcap Meeting. ACTION ITEM: Ian Simpson and Steve Tooley to analyze the supplier feedback and provide a summary to the Task Group. (Due Date: 3-Mar-2015). 3.1.4 Standard data set WELDING OCTOBER 2014 CONFIRMED The standard data set charts were reviewed by the Task Group. No specific items resulted from this review; however it was noted that once Modified cycle checklists are introduced this would likely skew the data, and as such it may be necessary to flag the data as standard cycle or modified cycle so that the data is not misinterpreted. ACTION ITEM: Ian Simpson to investigate the feasibility of segregating standard and modified scope audit data in the standard data set provided to the Task Group. (Due Date: 3-Mar-2015) ACTION ITEM: Ian Simpson to request modification of the standard data sets to allow for segregation between standard and modified scope data. Note that this request will be via the Annual report to NMC on NOP-012 implementation. (Due Date: 30-Nov-2014) The discussion on chart effectiveness also resulted in how the chart that defines where each auditor writes NCRs compared to specific checklist paragraphs could be manipulated to establish if there are statistical variations that could allow the Task Group to perform any deep dives. Brian Ricks volunteered to review this chart and establish if this is possible. ACTION ITEM: Brian Ricks to evaluate where each auditor is writing NCRs by checklist item and establish if there is variation that warrants further investigation by the Task Group. (Due Date: 3Mar-2015) 3.1.5 Auditor Observation plan / Observation reports The Task Group reviewed the Observation plan. Of the 8 Auditors who were identified for Observation this year, 7 have either been observed or are scheduled to be observed. Observations of any ‘high risk’ Auditors have been completed. Observations of other Auditors (i.e. not identified for Observation in 2014) have also been conducted. The Task Group again noted issues such as suppliers refusing Observations, rescheduling of audits etc. as limitations on their ability to meet the plan. The Observation plan for 2015 was drafted. The observation of the Auditor who was identified for a 2014 Observation that did not occur was made priority, along with routine observations of another 5 Auditors, and an additional one noted as a priority follow-up. ACTION ITEM: Ian Simpson to post the updated Observation plan in the Task Group’s working forum page in eAuditNet. (Due Date: 15-Nov-2014) The Task Group reviewed 6 Observations. The Observations noted some areas for improvement and the Staff Engineer was actioned to communicate these to the relevant Auditors. ACTION ITEM: Ian Simpson to communicate the Task Group’s comments to Auditors based on Observation reports. (Due Date: 15-Nov-2014) One of the Observation reports noted an issue in ISO 24394 that does not specifically require eyesight restrictions to be noted on the Welder Qualification Test Record. Holger Krueger stated that he would add this to the agenda for the next ISO working group meeting. 3.1.6 Annual Report to the NMC including proposed revisions to NOP-012 Steve Tooley and Ian Simpson drafted a summary report as required by NOP-012. This includes the Task Group progress towards complete compliance as well as suggestions for modification to the procedure. This was reviewed by the Task Group and a modified version agreed. Steve Tooley will present this to the NMC on behalf of the Task Group. ACTION ITEM: Steve Tooley to submit the Task Group’s NOP-012 annual plan to the NMC. (Due Date: 15-Nov-14) 3.1.7 Dashboard WELDING OCTOBER 2014 CONFIRMED A dashboard that incorporates the NOP-012 metrics was created for the June 2014 Nadcap meeting. This was updated prior to this meeting by the Staff Engineer and was reviewed by the Task Group. 3.1.8 Identify Training needs for Auditors The review of data defined here and also from item 2.0 has resulted in identified training items that have been added to a potential list of training items in 2015. 3.1.9 Remaining NOP-012 deliverables The Task Group has already completed the following items as required by NOP-012 Initial auditor training required for new Weld Auditors Proficiency testing. This was previously deemed not necessary based on the method the Task Group use to initially hire auditors and how they subsequently remove process restrictions An appendix to the Observation form was not deemed necessary as the standard form allows sufficient information to be noted Audit Report Reviewer assessment data was reviewed at the February 2014 meeting. This data only requires review annually 3.2 Ian Simpson provided an update of auditor restriction removals and new auditors entering the system. 4.0 SUPPLIER ADVISORIES – CLOSED 4.1 Review of Advisories since June 2014 Nadcap Meeting. Five Supplier Advisories have been issued by WLD since the last Task Group meeting, # 2488, #2496, #2505, #2518 and #2521. These were reviewed. No additional actions were identified. It was also noted that the Risk Mitigation associated with Supplier Advisory #2480 had been completed. A question was asked as to how a reply could be made to a supplier’s response should there be conflict in what the Risk Mitigation Team Reviewers were requesting. Steve Tooley subsequently requested clarification from this at the Planning and Operations meeting and was informed that in situations such as this, the NMC should be contacted to resolve the matter. Advisory #2521 requires Risk Mitigation. A team of Subscribers has been assigned for this. Two Supplier Advisories were issued by other commodities that could have an effect on WLD accreditations. These advisories, # 2507 and #2517 were reviewed. There was concern that both of these advisories were on the same Supplier. The NDT Task Group was consulted to establish if the item they issued was still a concern. The feedback provided indicated that they believed that the matter had been adequately resolved. From initial further investigation it was believed that General Electric (GE) were the only Nadcap Subscriber with welded product at this Supplier, hence they were asked to establish if any quality issues had been noted. GE subsequently confirmed that they had not experienced any issues with welded product from this Supplier. Review of Subscriber Advisories. No Supplier Advisories are required as a result of Subscriber declarations. 5.0 STAFF ENGINEER DELEGATION – CLOSED 5.1 The Staff Engineer reviewed data for Audit Report Reviewers using delegation oversight form tfrm-07, including percentage oversight by Task Group, percentage NCRs concurred with by the Task Group and other items pertaining to audit completeness. All requirements of NOP-003 were met for the delegated Audit Report Reviewers and the following Motions were made. WELDING OCTOBER 2014 CONFIRMED Motion made by Ralph Kropp and seconded by Gary Coleman to maintain Ian Simpson’s delegation. Motion Passed. Motion made by Ralph Kropp and seconded by Gary Coleman to maintain Mike Gutridge’s delegation. Motion Passed. Motion made by Ralph Kropp and seconded by Gary Coleman to maintain Wayne Canary’s delegation. Motion Passed. It was also noted that Stan Revers held delegation during this review period, but that he is no longer at PRI. The delegation data was viewed and no issues identified. 6.0 SUBSCRIBER DEVIATIONS – CLOSED 6.1 No Subscriber Deviations were requested for review. 7.0 NEW BUSINESS – CLOSED 7.1 At the June 2014 Task Group meeting, the Risk Mitigation process as required by NOP-011 for failed audits was explained. Since this process was introduced, the Task Group has only required two Risk Mitigation teams to be formed and each had different Subscriber members. Hence the procedural requirements were re-emphasized so that all Subscriber members are aware of the requirements. Also see item 4.1. 8.0 REVIEW MEMBERSHIP STATUS – OPEN The WLD Task Group reviewed the Membership status. 8.1 The following Subscriber members were noted as attending their first WLD meeting. 8.2 Saeed Cheema – Textron Inc. Brian Harvey - Gulfstream Aerospace Rodney Holt – Triumph Group Inc. Joe Sebastiani – Defense Contract Management Agency (DCMA) Jason Merrell - U.S. Air Force Tim Nance – Rockwell Collins, Inc. Hirohiko Hattori of Mitsubishi Heavy Industries attended his second meeting. The Task Group Chairperson agreed to the appointment of Hirohiko Hattori as Subscriber Voting Member (UVM) for Mitsubishi Heavy Industries and m-frm-01 was completed. Jerry Hulin of GKN Aerospace, Bristol attended his second meeting. At this time however the Subscription for GKN Aeropsace, Bristol does not include WLD. The annual Subscription renewal is however imminent and as such, The Task Group Chairperson agreed to the appointment of Jerry Hulin as UVM for GKN Aerospace, Bristol, subject to the Subscription being updated to include WLD. m-frm-01 was completed, but will not be implemented until the Subscription is updated. 8.3 Task Group meeting attendance and ballot participation was reviewed per Nadcap Operating Procedure NOP-001 requirements. Cessna Aircraft Company (now subscribing as Textron Inc.) have not balloted on 2 consecutive letter ballots and as such, per NOP-001 have lost their voting rights. Ken Sposato left the employment of Triumph Group Inc. on 01-Aug-2014. His Voting rights were removed at that time. Barnes Aerospace requested a change to their primary Voting member. i.e. for Angelo Monzo to become their Supplier Voting Member (SVM), with Gigi Streeter moving to Alternate Supplier Voting Member (ALT/SVM). WELDING OCTOBER 2014 CONFIRMED ACTION ITEM: Ian Simpson to add Hirohiko Hattori as UVM for Mitsubishi Heavy Industries. (Due Date: 15-Nov-2014) ACTION ITEM: Ian Simpson to add Jerry Hulin as UVM for GKN Aerospace, Bristol, once the Subscription has been updated to include WLD. (Due Date: 31-Dec-2014) ACTION ITEM: Steve Tooley to notify Jeremy Philips that his Voting Rights have been lost. (Due Date: 15-Nov-2014) ACTION ITEM: Ian Simpson to remove Voting rights for Jeremy Philips of Textron Inc. (Cessna Aircraft Company). (Due Date: 30-Nov-2014) ACTION ITEM: Ian Simpson to change Angelo Monzo to SVM and Gigi Streeter to ALT/SVM for Barnes Aerospace. (Due Date: 30-Nov-2014) 8.4 Richard Freeman of TWI Ltd has been acting as a Specialist to the Task Group for a number of meetings, predominantly to assist in the development of a checklist for Additive Manufacture. In this role Richard is attending all open meetings. Should specialist help be required to address any specific supplier issues on this process in the future, the Task Group Chair stated that he will invite Richard to some portions of closed meetings as allowed by NOP-001. 9.0 SUPPLIER SUPPORT COMMITTEE (SSC) REPORT – OPEN 9.1 Mike Schleckman gave a presentation on SSC Activities. This gave information on its role, current activities, the mentoring program and SSC initiatives and events. SSC provides an avenue for suppliers to have input and give feedback to the Nadcap system. Provides answers and support for suppliers who have questions and problems. Current activities involve mentoring suppliers, metrics, supplier surveys, help desk at Nadcap meeting, and education. 10.0 NADCAP MANAGEMENT COUNCIL (NMC) METRICS – OPEN 10.1 Ian Simpson reviewed the NMC metrics, including: Accreditations Issued/Lapsed, Eligible Merit, On-Time Certification, Staff Cycle Time Initial, Staff Cycle Time Reaccreditation, Task Group Cycle Time Initial, Task Group Cycle Time Reaccreditation, Supplier Cycle Time Initial, Supplier Cycle Time Reaccreditation. All metric charts were green, except Task Group Cycle Time Reaccreditation which was yellow. This nongreen metric has been previously discussed and the Task Group chose to take no further action. 11.0 SPECIFICATION CHANGES – OPEN 11.1 Gary Coleman provided an update on the status of American Welding Society (AWS) specifications. The current goal is to have the new revision of AWS D17.1 by 2016. Three major changes are likely; vision test; visual inspector training approval; procedure qualification. AWS D17.2 is currently under review with likely revisions to encompass real time adaptive control; flat vs. curved coupons; sheet separation limits; nugget diameter minimum value vs. metallographic values. AWS D17.3 has had comment resolution with the next step being a review by the Technical Activities Committee. AWS D17.1, D17.2 and D17.3 Committees will meet in the week commencing 11-Nov-14 at the FABTECH convention in Atlanta, GA. The Staff Engineer showed a comment from AWS. Prior minutes had noted that gaining QC1 certification of Visual Weld Inspectors outside of North America was a difficult proposition. AWS provided information that showed that they conduct many exams outside of North America and that the perceived difficulty in obtaining QC1 in other regions is not a true reflection of reality. AWS provided a link to their QC1 qualification page and is provided here for reference http://www.aws.org/w/a/registrations/prices_schedules_intl.html?noleft=1 WELDING OCTOBER 2014 CONFIRMED Holger Krueger provided an update on the status of ISO specifications. ISO notes that visual acuity remains an issue and they are currently reviewing 3 alternatives; ISO 16338 (resistance weld) – there are errors in the shear force requirements and also a clarification in the clear annulus zone that is to be addressed; ISO 24394 is due for review and will include an enhancement of the table that depicts test piece and weld position; ISO 11745 AMD 1 will introduce improved eyesight test requirements; ISO 17533 is for welding design and will be released soon; ISO / PWI 17927 is for fusion welding, but it will likely take some time to complete; a new work item for Visual inspection has been added; the Committee continue to look at other weld processes for ISO specification control, i.e. Additive Manufacture, Electron beam and Laser beam welding. The ISO Committee will meet the week prior to the March 2015 Nadcap Meeting at DIN in Berlin, Germany. Their autumn meeting will be the week prior to the Nadcap October 2015 meeting at Boeing’s Renton, WA facility. Holger Krueger gave permission for the ISO Committee update to be posted in eAuditNet. This will be added to the Public Documents section for Welding (Resources / Documents / Public Documents / Welding / Data Folder). ACTION ITEM: Ian Simpson to post the ISO Committee update presentation in eAuditNet. (Due Date: 15-Nov-2014) 12.0 HYDROGEN GENERATOR – OPEN 12.1 Discussion on the use of Hydrogen Generator in the braze process An update of the process was given at the June 2014 Nadcap Meeting by Scott Maitland. At that time the Task Group decided that they required more information in order to establish if a checklist to control this process is required. Scott Maitland provided an update at this meeting. There does not appear to be any specifications that control this process. Generic literature of how the process is controlled has also not been forthcoming. There are concerns that the theoretical ratio of hydrogen to oxygen of 2:1 has to be significantly exceeded to ensure an oxidizing flame is not used. It was suggested that trials may have to be implemented to assess the levels of oxygen that are present in the flame. Gary Coleman and Richard Freemen agreed to work with Scott Maitland to determine possible process control mechanisms and report back to the Task Group at the March 2015 meeting. ACTION ITEM: Scott Maitland, Gary Coleman and Richard Freeman to obtain additional information on controlling specifications, process control mechanisms and other key information on hydrogen generator brazing and report back to Task Group at the March 2015 meeting. (Due Date: 4-Mar-15) 13.0 FORUM FOR SUPPLIER ISSUES – OPEN Vision test requirement discussion initiated by Jackie Sternot to ensure the proposed changes to AWS D17.1 will allow more options for testing and not add more requirements. Gary Coleman confirmed that it was the intent to give more options and not additional requirements. 14.0 ADDITIVE MANUFACTURE – OPEN At the June 2014 Nadcap Meeting, the sub-group of Richard Freeman, Scott Maitland and Robbie Adams presented a draft checklist to the Task Group. The draft was reviewed and comments made for consideration by the sub-group. Chris English also volunteered to join the sub-group. WELDING OCTOBER 2014 CONFIRMED At this meeting, Richard Freeman presented the current state of the Additive Manufacture draft checklist. They have re-formatted to move powder control into the baseline portion of the checklist, utilized language for powder control based on existing Coatings checklist questions and incorporated comments from the June 2014 Nadcap Meeting. The sub-group is trying to gain information from equipment suppliers but although they are, in general, keen to help, the necessary information has not yet been forthcoming. It was noted that a checklist could not be introduced without it being based on specifications, but the Task Group stated they need to start development otherwise they will not be able to catch-up once specifications are released. Compliance against NOP-002 checklist vision will be assured prior to issue. The latest draft was reviewed and comments made by the Task Group. The sub-group will continue to work on the development of the checklist and will address the Task Group again at the March 2015 Nadcap Meeting. ACTION ITEM: Sub-team of Richard Freeman, Scott Maitland, Robbie Adams and Chris English to address Task Group comments, revise draft Additive Manufacturing checklist as needed and report back to the Task Group at the March 2015 Nadcap Meeting. (Due Date: 4-Mar-15) 15.0 TOP 10 NCR GUIDANCE – OPEN At the June 2014 Nadcap Meeting, a sub-group of Scott Maitland, Mike Schleckman, Lyle Morris and Ian Simpson was formed to review if guidance could be provided for the top 10 NCRs in an attempt to help suppliers understand why these NCRs keep re-occurring and ultimately suggest methods to prevent this. The Task Group had performed a similar task many years ago, but as some of the top 10 NCRs have changed, it was thought that revamping this would be beneficial. At this meeting, the sub-group presented a proposal for top10 NCR guidance. This was reviewed by the Task Group and minor modifications made. The Task Group approved the document and instructed the Staff Engineer to post the document in eAuditNet. (Resources / Documents / Public Documents / Welding / Supplier Information). ACTION ITEM: Ian Simpson to post the top 10 NCR Guidance document in eAuditNet. (Due Date: 15-Nov-2014) 16.0 NEW BUSINESS ITEMS – OPEN 16.1 GE Aviation suggested that the Task Group should discuss the requirements for calibration of electron beam weld equipment. While calibration of gauges is almost certainly a requirement in all specifications, there is some greyness about the need to calibrate the direct power output. AC7110/3 paragraph 5.2 is quite generic and does not specify which is required. In order to provide further guidance, subscribers will need to establish what they require. Should all require direct power calibration, the question could be revised, however, if this is a requirement of only a few subscribers then the likelihood is that Supplemental checklist requirements would be defined. Until such time this information is known, no changes can be made. Hence all Subscribers were requested to collect this information for discussion at the March 2015 Nadcap Meeting. ACTION ITEM: Subscribers to assess the need to add clarification to the Auditor Handbook and / or determine the need for a checklist supplement with respect to electron beam weld machine calibration. (Due Date: 4-Mar-2015) ACTION ITEM: Ian Simpson to add an agenda item for the March 2015 Task Group meeting to discuss calibration requirements for electron beam welding. (Due Date: 15-Nov-2014) Minimum penetration for resistance spot welding (RSW) – Milan Hanyk presented differences of specification requirements to RSW nugget cross sectional profiles. Milan has submitted an interpretation request to AWS on this matter and will provide an update to the Task Group when a reply is received. WELDING OCTOBER 2014 CONFIRMED A question was asked about the selection of parts on modified cycle audits. The Job selection handbook was shown. Suppliers were advised to review as modified cycle audits will have an additional job audit per checklist. The Job selection handbook is posted in eAuditNet with the other Weld Handbooks (Resources / Documents / Public Documents / Welding / Audit Information). 17.0 CREATE NMC FEEDBACK CHART – OPEN 17.1 The Task Group generated the feedback chart for presentation by Steve Tooley at the NMC meeting. 18.0 EQUALIFIED WELDING REVIEW BOARD UPDATE – OPEN 18.1 Justin McCabe from PRI addressed the Task Group to inform them that the eQualified Review Board had selected Weld for development of a qualification program. Justin informed the Task Group of how the process had worked for other commodities and that the kick-off meeting with interested bodies in Welding had identified potential areas of development for resistance welding, laser beam welding and electron beam welding. Les Hellemann suggested that the program could encompass an Aerospace specific Visual Weld Inspector qualification and that this could then be adopted by subscribers as a qualification that allows them to approve these individuals to meet AWS D17.1 paragraph 7.1.2. The presentation will be posted in eAuditNet. (Resources / Documents / Public Documents / Welding / Supplier Information) Additional information on the eQualified Program is available on www.p-r-i.org (Professional Development / Qualifications) One slide reported that qualification would support Part 21 and Part 145 compliance. This was questioned and Justin McCabe actioned to establish where this statement had originated. ACTION ITEM: Ian Simpson to post the presentation on eQualified in eAuditNet. (Due Date: 15Nov-2014) ACTION ITEM: Justin McCabe to investigate how the program may be used to support Part 21 and Part 145 compliance. (Due Date: 30-Nov-2014) 19.0 AUDITOR ADVISORIES – OPEN 19.1 One Auditor Advisory has been issued since the June 2014 Nadcap Meeting. This was reviewed by the Staff Engineer. The Task Group was reminded that these are posted in eAuditNet (Resources / Documents / Public Documents / Welding / Auditor Advisories). 20.0 NTGOP 001 APPENDIX BALLOT DISPOSITION – OPEN 20.1 At the June 2014 Nadcap Meeting, potential revisions to the Weld specific appendix of NTGOP001 were discussed. The main item of discussion was revision of paragraph 6.0 to further define rules surrounding the use of smart checklists. At this time it was noted that the terminology could be confusing and as such a sub-group was formed to review the terms, modify the verbiage in this section and subsequently ballot the procedure. During discussion it became apparent that the confusion of terms stemmed from a change in how the NMC sub-group had determined the method for smart checklists should work. The Weld subgroup sought clarification from the NMC sub-group lead, Bob Koukol, as to how this could be resolved. It is noted that the NMC and the Weld Task Group are clear in how the technology is WELDING OCTOBER 2014 CONFIRMED used and that this is simply a terminology issue. On this basis, the Weld sub-group revised the verbiage to simply define the terms used in eAuditNet and remove the terms used by NMC. The procedure completed Task Group ballot on 15-Oct-14 with no comments, hence the Staff Engineer will complete the ballot process by balloting to NMC. ACTION ITEM: Ian Simpson to ballot NTGOP-001 Appendix WLD to NMC. (Due Date: 30-Nov-14) 21.0 NMC MEETING REPORT – OPEN 21.1 Steve Tooley gave a summary of key items that were discussed in the Chair / Staff Engineer roundtable meeting on NOP-012, Planning and Operations meeting and NMC meeting. Key items were: The NMC have appointed a sub-team to review the Task Group cycle time metric Observation Audit data for weld shows that 20 observations were requested; 12 completed, 4 rejected by Supplier, 4 cancelled by Observer Expectation of NMC is for face-to-face meetings with auditors annually 22.0 CHECKLIST ITEMS – OPEN 22.1 Handbook revisions The Staff Engineer presented possible revisions to the AC7110/12 handbook. This was reviewed by the Task Group and agreed. These were administrative changes to align correctly with the checklist. The Staff Engineer presented possible revisions to the AC7110/5 handbook. These included guidance on electrode control, multi-pass welds used on hardfacing and tack weld definition. This was reviewed by the Task Group and agreed. It was noted that some of these revisions will also apply to other handbooks. The auditors requested that Boeing revise their guidance on performance to reflect that this needs to review acceptability of welds and not simply that the welder has welded. This is in relation to extended validity in AC7110/12S paragraph 3.20. Boeing agreed to provide additional guidance. ACTION ITEM: Ian Simpson to issue revised handbook for AC7110/12. (Due Date: 30-Nov-2014) ACTION ITEM: Michael Irvin to provide revised guidance for AC7110/12S paragraph 3.20. (Due Date: 15-Nov-2014) ACTION ITEM: Ian Simpson to issue revised handbook for AC7110/12S. (Due Date: 30-Nov-2014) ACTION ITEM: Ian Simpson to incorporate agreed revisions into all appropriate handbooks and issue revised handbooks. (Due Date: 30-Nov-2014) 22.2 Checklists revisions The Staff Engineer confirmed that the resistance weld checklist had been issued with an effectivity date of 30-Nov-2014. The Staff Engineer confirmed that the checklist for torch and induction brazing, AC7110/1, had been approved by NMC and as such PRI will issue it as soon as possible. As it affects accreditation it will have the minimum 90 day implementation period imposed. The Staff Engineer has updated the handbook with the same verbiage as used in the AC7110/5 handbook to explain how standard and modified cycle checklists will be used. Other changes were presented to WELDING OCTOBER 2014 CONFIRMED accommodate other checklist changes. The Task Group reviewed and revised as necessary. The handbook will be issued when the AC7110/1 checklist is issued. ACTION ITEM: Ian Simpson to issue AC7110/1 Rev G and associated handbook. (Due Date: 31Dec-2014) The electron beam weld checklist was revised to allow modified cycle audits and also incorporate items from the rolling list of checklist items. This was balloted to the Task Group. Formal notification was sent that resolution of comments would be addressed at this meeting. Each ballot comment was reviewed and addressed. Changes that were agreed are all editorial, hence the Staff Engineer is able to incorporate and ballot directly to the NMC without the requirement for a further ballot to the Task Group. The Task Group did however note that although some of the proposed revisions would not be incorporated at this revision, that they should be added to the rolling action item list for incorporation into future checklist revisions. ACTION ITEM: Ian Simpson to complete ballot resolution process for AC7110/3 and subsequently ballot to NMC. (Due Date: 15-Nov-2014) ACTION ITEM: Ian Simpson to add proposed revision of AC7110/3 paragraph D.1.9 through D.1.11 to the rolling action list of proposed checklist revisions. (Due Date: 15-Nov-2014) Since the June 2014 meeting, the supplemental checklists have been successfully balloted to revise requirements for GE Aviation and MTU Aero Engines AG. These, as well as the associated handbooks, have subsequently been issued with an effectivity of 11-Jan-2015. The Task Group maintains a rolling list of items for requests on checklist revision. Since the last Task Group meeting, 3 items were added and dispositioned by the Task Group: A proposal for the deletion of AC7110/1 paragraph 4.3.5.6 as proposed in the ballot of AC7110/1 for future consideration was rejected; revision to AC7110 paragraph 5.3 as suggested at the Auditor Conference was partially agreed in that the Task Group dispositioned that clarification should be via the handbook and not a checklist revision (this was also agreed in paragraph 22.1); a suggestion to add laser weld tacking prior to electron beam welding was not agreed, however the Task Group did agree that tacking control should be made more generic and remove the currently specific GTAW tack welding at future revisions. 22.3 Smart Checklist The next checklist identified for revision to allow modified cycle audits is Laser Welding, AC7110/6. The Staff Engineer has drafted this checklist using the same philosophy that has already been used on previously revised checklists. It has also incorporated all relevant items from the rolling list of action items. The Staff Engineer was actioned to add any related items from the disposition of comments on AC7110/3 and then ballot it. ACTION ITEM: Ian Simpson to ballot the AC7110/6 checklist. (Due Date: 30-Nov-2014) The Task Group agreed that the next checklist to be modified would be the welder / weld operator qualification checklist, AC7110/12. The Staff Engineer has started to draft the revision and has incorporated the items form the rolling list. The Staff Engineer suggested that it would be beneficial to have a sub-group of individuals with knowledge of the Industry qualification specifications formed to review the draft. A sub-team of Michael Irvin, Holger Krueger and Bob Fletcher was formed to review the draft checklist with the intent of a pre-ballot review at the March 2015 Task Group meeting. ACTION ITEM: Sub-team of Michael Irvin, Holger Krueger and Bob Fletcher to present draft of AC7110/12 at the March 2015 meeting. (Due Date: 4-Mar-2015) WELDING OCTOBER 2014 CONFIRMED 23.0 MARCH 2015 NADCAP MEETING AGENDA – OPEN The Task Group agreed that priority items include: revision of the remaining checklists to smart checklist format; Additive Manufacture; review / analyze Auditor Consistency data. The Staff Engineer was requested to establish if any regular agenda items are required to be added and then to draft the agenda. 24.0 REVIEW OF ACTION ITEMS – OPEN All action items were reviewed for proper assignment and due date. 25.0 REVIEW OF MEETING EFFECTIVENESS – OPEN The meeting was considered to be effective in meeting its goals. It was suggested that internet access should be available to assist members in obtaining any relevant material that is useful to meeting discussion items. 26.0 NEXT MEETING – OPEN As the format of the March Nadcap Meeting includes the NMC meeting on Thursday morning, the Task Group requests to meet Tuesday to Thursday. Hence the meeting will be 3-5-Mar-2015 in Berlin, Germany. ADJOURNMENT – 23-OCT-14 – Meeting was adjourned at 5:00 p.m. Minutes Prepared by: Les Hellemann (les.hellemann@ge.com) 20/21-Oct14, and Mario Leclerc (Mario.leclerc@aero.bombardier.com) 22-Oct-14 ***** For PRI Staff use only: ****** Are procedural/form changes required based on changes/actions approved during this meeting? (select one) YES* ☒ NO ☐ *If yes, the following information is required: Documents requiring revision: Who is responsible: NTGOP 001 App WLD Ian Simpson Due date: 30-Nov-14 (for ballot to be sent to NMC)