HEAT TREATING OCTOBER 2010 UNCONFIRMED MINUTES OCTOBER 18 – 21, 2010 PITTSBURGH MARRIOTT CITY CENTER PITTSBURGH, PENNSYLVANIA 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, OCTOBER 18 to THURSDAY, OCTOBER 21, 2010 1.0 OPENING COMMENTS 1.1 Call to Order / Quorum Check The Heat Treat Task Group (HT) was called to order at 8:00 a.m. on 18-Oct-10. The HT Staff and Subscriber participants were introduced. 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 * * * * * * * * * * * John Silvia Bruce Frank Giuseppe Craig Dave Martin Ron Martin Mark Marion Laurent Troy Peter Mohammed Gerald W. Eddie Andy Billy Dave Kent Jeff Holger COMPANY NAME Anderson Baeza Brownfield Brungs Campanile Clasper Damasauskas Day deJesus Dixon Emerson Foster Geerts Grim Hammarbo Haq Harvey Hofer Hopkins Hulse Isenberg Johnson Koss Krueger US Air Force Triumph Group, Inc. Lockheed Martin Corporation MTU Aero Engines GmbH Alenia Aeronautica SpA General Dynamics Spirit AeroSystems, Inc. Honeywell Aerospace Goodrich Corporation Hawker Beechcraft Corporation Rolls-Royce Corp. Spirit AeroSystems, Inc. Sonaca SA Spirit AeroSystems, Inc. Volvo Aero Corporation Bell Helicopter Textron Triumph Fabrications - Hot Springs Inc. Rockwell Collins, Inc. BAE Systems MAS Spirit AeroSystems, Inc. Parker Aerospace Group 309th Maintenance Wing- Hill AFB The Boeing Company Airbus 1 HEAT TREATING OCTOBER 2010 Subscriber Members/Participants Present (* Indicates Voting Member)(Contd) NAME * * * * * * * * * * * Serge Joey William Doug Jacob Tom Mitch Eddy Richard Earl Sundar Chris Alex Andre Victor Gary Kashi Sally William Jeffrey Cyril Michael Gary Peter Grzegorz COMPANY NAME Labbe Latkowski Macias Matson Milo Murphy Nelson Pham Poulsen Pruett Rajan Reilly Richez Roy Schonberger Sigmon Singhal Soliman Stewart Thyssen Vernault Walker Wallace Wong Wryk Heroux-Devtek, Inc. United Space Alliance Goodrich Corporation The Boeing Company IAI - CAG - SHL PD & ENG Divisions Sikorsky Aircraft Cessna Aircraft Company Northrop Grumman Corporation 309th Maintenance Wing- Hill AFB Lockheed Martin Corporation Raytheon Co. Hamilton Sundstrand Airbus Bombardier, Inc. Israel Aerospace Industries 309th Maintenance Wing- Hill AFB Bell Helicopter Goodrich Corporation Bombardier, Inc. GE Aviation SAFRAN Group Spirit AeroSystems Parker Aerospace Group Goodrich Corporation Goodrich Corporation Other Members/Participants Present (* Indicates Voting Member) NAME * * Roy Abdul Bob Zubair Daniel Doug David Griff Micky Michael Mike Mark Christopher David Wolfgang Richard Yongho Stephen Delbert Tina Terrance Robert COMPANY NAME Adkins Admani Akin Alam Antos Billings Bowles Braddock Bradican Brandt Brausch Brown Bryant Bullard Casta Chmielewski Cho Choma Clubine Corbin Curtain Cvetichan Specialty Steel Treating Arrow Gear Quality Heat Treating Exactatherm Ltd. Canton Drop Forge Parker Hannifin Pressure Technology, Inc. Braddock Metallurgical, Inc. Applied Thermal Technologies Alcoa, Inc. CCPI, Inc. Braddock Metallurgical, Inc. Carpenter Technology Corporation Hi-Tech Metal Finishing Shellcast Foundries The Barden Corporation, Inc. Avibank Manufacturing, Inc. Vac-Met, Inc. Advanced Heat Treat Corp. Haynes International, Inc. Aetna Plating Company American Brazing Corp. 2 Chairperson Vice Chairperson HEAT TREATING OCTOBER 2010 Other Members/Participants Present (* Indicates Voting Member)(Contd) NAME * * John Jason Roger Patrick Bill Mitch Sarah Bob T.J. Jay Matt Michael Susan George Lisa Stephan Scott William James Randolph Steve Jennifer Stephen Kurt Zia Adeel Amanda Alexander Ryan Ron James Bob * Johanna * Donald James Kip Giuseppe Gary Mathew Christopher Abdul Michael Mark Jesse COMPANY NAME Davies Deysher Dunn Durkin Erzen Evans Fuqua Ferry Fitzmaurice Ford Gargano Gaspers Generalovich Gieger Goodwin Greimers Hasty Hewson Hill Hite Hutchinson James Johnson Jungheim Karim Karim Kirchner Klyuch Kollmorgen Kramer LaFollette Lehnen Bristol Aerospace LTD Carpenter Technology Corporation Bodycote Thermal Processing - Cincy TE Wire &Cable PAKO, Inc. Braddock Metallurgical, Inc. Kearfott Corp. FPM Heat Treating LLC TSI Titanium Curtiss Wright Controls, Inc. Eng Systems Solar Atmospheres of Western PA FPM Heat Treating LLC Solar Atmospheres of Western PA Braddock Metallurgical, Inc. Jorgensen Forge Corp. ThyssenKrupp VDM GmbH Valley Heat Treat Bodycote IMT, Inc. Carpenter Technology Corporation PCC Structurals, Inc. LPC Braddock Metallurgical, Inc. Precision Tube Co. GSC - Steel Plant Modern Drop Forge Co. Heat Treat Pro Doctor Furnace, Inc. Beyond Relations Blades Technology Ltd Specialty Steel Treating, Inc. Gulfstream Aerospace GeoCorp, Inc. Bodycote Thermal Processing Lisa Continental and Quality Heat Treating & Valley Metal Treating Lowman Maloney Martin Marzano Merrill Nadakal Napoli Nathani Niedzinski Nigels Norris Continental Heat Treating Timken Aerospace Alcan Rolled Products-Ravenswood Haley Industries, Ltd. M7 Aerospace TE Wire and Cable Allegheny Ludlum Hi-Tech Metal Finishing Alcan Rhenalu - Issoire Plant Parker Hannifin Stack Metallurgical Services 3 HEAT TREATING OCTOBER 2010 Other Members/Participants Present (* Indicates Voting Member)(Contd) NAME * * * Jim John Art David Rozalia Timothy Scott Larry Kevin Crystal Tyler Michael William Martin Barry Elena James Glen Guy Carol Bill Kevin Ray Steve Stuart Deepak Janet Mark Jon George Gary Robert James Paul William Richard Edward Wilfried Keith Terry David COMPANY NAME Oakes Ochenas Onaitis Osenar Papp Paradis Peterson Phipps Pludeman Potter Pounds Quann Rae Reicher Reid Ritoli Robellard Rudd Saenz Schmidt Schultz Seidel Serrato Shea Sherman Singhal Skaggs Sobota Steltenpohl Stoffa Thomas Thompson Varghese Vegiard Wadsworth Walker Warter Weber Whiddon Wilkison Wootton Super Systems, Inc. GeoCorp, Inc. Precision Tube Co. PAKO, Inc. Air Liquide US LP Metallurgical Processing, Inc. Beyond Relations Alcoa Fastening Systems Cornerstone Systems, Inc. Valley Heat Treat Co. Northstar Aerospace Chicago, Inc. Pacific Metallurgical, Inc. CAV Aerospace Ltd. Bohler Schmiedetechnik GmbH & Co KG Shur-Lok Corp. Metallurgical Processing, Inc. Plymouth Tube Company Braddock Metallurgical, Inc. Hi-Tech Metal Finishing Ladish Forging Braddock Metallurgical, Inc. Carpenter Technology Corporation Valley Metal Treating Scarrott Metallurgical Metallurgical Processing, Inc. Industrial Tectonics Bearings Corp. Leonard's Metal, Inc. TSI Titanium Paulo - Kansas City Pressure Technology, Inc. Alexco Steel Treaters, Inc. Pressure Technology, Inc CCPI, Inc. Carpenter Technology Corporation Pressure Technology, Inc. Carmel-Forge Ltd PFW Aerospace AG Canton Drop Forge, Inc. Unison Engine Components - Terre Haute Lisi Aerospace 4 HEAT TREATING OCTOBER 2010 PRI Staff Present Jerry Marcel Rob Joe Lisa 1.3 Aston Cuperman Hoeth Pinto Zajacs Approval of Previous Meeting Minutes - CLOSED The minutes from June 2010 were approved as written. 2.0 HEAT TREATING TASK GROUP TUTORIAL – CLOSED The meeting began with a reading of the Nadcap Code of Ethics and Conflict of Interest and AntiTrust Policy. The Chair reminded the Task Group of the following: The feedback form for meeting facilitation will be done as a group at the end of the meeting. One microphone is available for anyone who would like to use it. Speak clearly, do not dismiss people’s opinions, emotional and off topics should be avoided. A presentation was given on Task Group leadership, support staff, eAuditNet Process in detail regarding each step required, operational requirements list (Review of Operational Requirements)NIP (Nadcap Internal Procedure), NTGOP (Nadcap Task Group Operating Procedure), NOP (Nadcap Operating Procedures), and Quality Manual AS7003, procedural hierarchy, procedure map, important procedures, group history, scope, mandates, NMC metrics (mandating Subscribers), group actions, current activities, meetings, and additional available information. 3.0 RAIL REVIEW - CLOSED The RAIL was reviewed, and the progress on closing prior meeting action items was reviewed. The RAIL document can be found at: www.eAuditNet.com under Documents / Public Documents / Heat Treating. The Task Group was reminded that the RAIL is updated on www.eAuditNet.com on the 15th of every month. It was agreed that PRI will send reminders to the Task Group when the RAIL is updated. 5 HEAT TREATING OCTOBER 2010 4.0 AUDIT FAILURE ANALYSIS AND VCA REPORT OUT – CLOSED The Staff Engineers presented to the Task Group the number of VCA audits being carried out per quarter. The number of VCA audits for the third quarter 2010 was10 of which 2 audits failed. This was an increase from the previous quarter when 9 VCA audits were conducted with 1 audit failing. The Task Group confirmed that each audit is treated on its own merits regarding required follow up actions, and there had been no changes in the way they determine the need for a VCA audit. It was discussed whether guidelines for requiring VCA audits should be produced, and it was agreed that a sub-team should be created to produce ‘guidance rules’ for when a VCA is required. The Task Group asked the Staff Engineers to present fourth quarter data at the February 2011 meeting. ACTION ITEM: Staff Engineers to report Failure and VCA analysis data at the next meeting. (DUE DATE: 28-Feb-11) ACTION ITEM: Sub-Team to produce ‘guidance rules’ for when a VCA audit is required. Sub-Team: Jeff Thyssen, Mark Emerson, Martin Day. (DUE DATE: 28-Feb-2011) 5.0 LAPSED ACCREDITATION – CLOSED The Staff Engineers presented to the Task Group the number of Suppliers who will have their accreditations lapse for the October 2010 quarter. There will be three Suppliers who will lapse, all associated with the number of cumulative late days. The Task Group was reminded that every Monday they get an email list of Suppliers whose cycle time exceeds 60 days. Subscribers are encouraged to work with the Suppliers to help close these audits. 6.0 SE DELEGATION– CLOSED Motion made by David Damasauskas & seconded by Silvia Baeza to continue to delegate Jerry Aston. Motion Passed Motion made by Jeff Thyssen & seconded by Mitch Nelson to continue to delegate Rob Hoeth. Motion Passed Motion made by Jeff Thyssen & seconded by Mark Emerson to continue to delegate Marcel Cuperman. Motion Passed Motion made by Mark Emerson & seconded by Tom Norris to continue to delegate Anne Allen. Motion Passed 6 HEAT TREATING OCTOBER 2010 7.0 AUDITOR CONSISTENCY– CLOSED The Staff Engineers presented to the Task Group where there had been a change from the previous audit of +/- 5 NCRs or greater. From this information, Auditors could be highlighted who may be showing a weakness in the number of non conformances that they find. It was agreed that when a Subscriber is to carry out an observation audit, that they try and include these Auditors on the audits they observe. This information will then be reviewed by the Task Group at Task Group meetings. Doug Matson gave a presentation on Auditor variation. The presentation included average number of NCRs raised for year 2008 (4.6%), 2009 (4.5%), and 2010 (4.7%). This showed that the average number of NCR has not changed very much over the last 3 years. The presentation also included a bar chart showing average number of NCRs per Auditor for 2010. Discussions were held on what information the bar chart was giving. It highlighted Auditors who raise a lot of NCRs and Auditors who only raise a few NCRs. Due to the way the information was presented, the information could be skewed by a number of factors including the number of audits performed, initial vs. re-accreditation audit, etc. It was agreed that the Task Group needs to determine how best to use the data to identify the ‘weak’ Auditors. Doug Matson also presented a slide, showing where Suppliers who were on merit subsequently lost merit on the next audit. This happened in 16% of audits in 2009 and 17% in 2010. Discussions on this highlighted various possible causes including a worsening of Supplier performance and Auditor inconsistency. It was reported that there is a NMC sub-team working on auditor consistency, of which Doug Matson and Marcel Cuperman are part of the team. It was agreed that Doug Matson would update the Task Group on the progress of the sub-team at February 2011 Task Group meeting. The Task Group had previously identified the top ten “Always Questions” from the HT checklists that can be used to monitor auditor consistency, and the results were presented to the Task Group showing audits where an Auditor raised an NCR where the previous Auditor had not. It was agreed that a sub-team would be formed to review and analyze the data, and report out the finding at the February 2011 Task Group meeting. ACTION ITEM: Sub-Team to review Top Ten questions data and report the findings at the February 2011 meeting. Sub-team: Jeff Thyssen, Tom Murphy, Mitch Nelson, Mark Emerson. (DUE DATE: 28-Feb-11) 8.0 AUDITS OBSERVERS REPORT OUT - CLOSED When a Subscriber carries out an oversight audit at a Supplier, Nadcap is requesting that they complete the oversight form, and return it to John Barrett at PRI. This allows the forms to be reviewed and discussed at the Task Group meetings. Since the last meeting, eight oversight audit forms have been returned and their summaries were reviewed by the Task Group. In general, the feedback on the Auditors was positive, but it does show areas that can be improved. These will be worked with those Auditors by the Staff Engineers. Audit observation reports will be reviewed each subsequent meeting. 7 HEAT TREATING OCTOBER 2010 9.0 AQS LIAISON REPORT– CLOSED No AQS liaison report was available for this meeting, due to the AQS representative no longer attending the Heat Treat Task Group meetings. Bruce Brownfield (Lockheed Martin) was voted in as AQS Liaison representative. 10.0 AUDITOR’S CONFERENCE DEBRIEF – CLOSED A summary was given of the Auditor Conference. The Auditor Conference concentrated on auditor consistency. The major output was a RCCA activity which was carried out by the Auditors to identify where inconsistencies arise and corrective action to improve consistency. Some of the areas highlighted was auditor knowledge of a particular process, training given to Auditors, and checklist content. There is a sub-team in place to review the information raised by the Auditors. Other topics reviewed were the modifications to checklists and the Process Control Matrix. The following checklist changes were debriefed: AC7102/1 AC7102/6 AC7102/5 AC7102/2 11.0 - Brazing (Jeff Thyssen) - HIP (Tom Norris) - Hardness (Mitch Nelson) - Conductivity/Aluminum (Doug Matson) NTGOP-001 APPENDIX 3 CHANGE PROPOSAL – CLOSED As per procedural requirements, NTGOP-001, Appendix III, was reviewed and updated. The Task Group approved the changes. ACTION ITEM: Staff Engineers to issue revised NTGOP-001, Appendix III. (DUE DATE: 28-Feb-11) 12.0 APPEALS ANALYSIS – CLOSED There have been no Supplier appeals since the June 2010 meeting. 13.0 S-FRM-05 ENHANCEMENTS – CLOSED The Task Group was debriefed that modifications have been made to the way Supplier information is displayed in eAuditNet. The On-Line QML section in eAuditNet has been changed to not only show the accreditation scope as defined by the Task Group, but also an information only section, which shows the industry specification the Supplier states they can work to. There is a disclaimer in the information section to ensure that it is recognized that the industry specifications are not Nadcap accredited as the specifications referenced may not have been audited. The Task Group has requested that the disclaimer statement is reviewed further for clarity. ACTION ITEM: Marcel Cuperman to review the disclaimer statement further for clarity. (DUE DATE: 28Feb-11). 8 HEAT TREATING OCTOBER 2010 14.0 TG CHAIR APPROVAL OF JUNE MINUTES – OPEN The Nadcap Heat Treating minutes were read in the open meeting and approved as read. 15.0 AC7102 REV. F BASELINE COMMENTS – OPEN Ballot comments were reviewed and addressed. AC7102 Rev. F will now be balloted to the NMC. 16.0 CLOSED MEETING AND AUDITOR CONFERENCE DEBRIEF – OPEN The HT Chairman debriefed the closed meeting discussions to the Suppliers in the open meeting. 17.0 NMC METRICS – OPEN The NMC metrics for the Heat Treating Task Group were presented. The NMC metrics show that the Heat Treating metrics are green. 18.0 AC7102/5 REV. A HARDNESS COMMENTS – OPEN Checklist AC7102/5 Rev. A has passed the NMC ballot and is ready to be issued. 19.0 CHANGES IN AC7102/5 REV B – OPEN The sub-team lead by Mitch Nelson presented the proposed changes to AC7102/5 Rev B. Highlights of the proposed changes are: Clarification of wording to allow hardness values to be reported as averages, where the customer requires it. Temperature requirements during daily verification testing clarified. Formatting changes were made to the checklist. 20.0 AMEC MEETING DEBRIEF – OPEN Doug Matson gave a summary of the topic being worked on by the AMEC committee. For additional information, please refer to the AMEC web site at: http://www.sae.org/servlets/works/committeeHome.do?comtID=TEAAMSAMEC 21.0 AC7102/6 HIP BALLOT COMMENTS – OPEN The AC7102/6 Hot Isostatic Pressure ballot comments were discussed, and each of the ballot comments resolved. The checklist will be balloted as a 14 day Affirmation ballot to the Task Group voting members and then it will be balloted to the NMC. 9 HEAT TREATING OCTOBER 2010 22.0 AUDITOR ADVISORIES – OPEN All the Auditor Advisories created since the beginning of the year were presented and reviewed during the open meeting. Auditor Advisories are found on eAuditNet in Documents, Heat Treating. 23.0 AC7102/4 REV. B NITRIDING COMMENTS – OPEN The AC7102/4 Nitriding ballot comments were discussed and each of the ballot comments was resolved. The checklist will now be balloted to the NMC. 24.0 HTTG CHAIR REPORT TO NMC – OPEN Mark Brown gave the HTSTSTG Chair report. Items covered include: - Process Control Matrix - Electronic signatures on electronic charts. - ASTM E384 - Non specification driven checklist questions - Sub-team for binary 10 See HTSTSTG minutes located in Public Documents for further information. 25.0 SSC REPORT – SUPPLIERS – OPEN Jon Steltenpohl gave a presentation of the current SSC activities. The topics covered were: - Metrics - Supplier Survey - Communication - Mentoring The SSC meets from 4:00 – 6:00 PM on Tuesday during each Nadcap meeting. Contact details: NadcapSSC@sae.org 26.0 PLANNING & OPS DEBRIEF – OPEN See the Planning & Ops minutes which are posted on the PRI website. 10 HEAT TREATING OCTOBER 2010 27.0 QUESTIONS AND ANSWERS SESSION – OPEN A good Question and Answer session was held with the Suppliers covering heat treatment questions. The main question covered was, “what are the expectations for electronic signatures on electronic charts”. The guidance given is that the signature must be on the electronic chart, or on a print out of the chart, or signed on a PDF file. A sub-team was formed to clarify the requirements and for this to be added to the Auditor Handbook. The Checklist question will also be reviewed for clarity. ACTION ITEM: Sub-team to clarify the requirements for electronic signature, and review the clarity of the checklist question. Sub-team: Doug Matson, Mitch Nelson, Jeff Thyssen, Mark Emerson, Martin Day, Rodger Dunn, Joanna Lisa, Bob Ferry. (DUE DATE: 28-Feb-2011) 28.0 OPENING COMMENTS – CLOSED 29.0 AUDITS ALLOCATION – CLOSED Audit reviews were allocated to the Subscribers. 30.0 FEBRUARY 2011 AGENDA – CLOSED The agenda was agreed upon for the February 2011 Nadcap meeting. This will be posted on the PRI web site. It was agreed that for the February 2011 meeting a sub-team will review the five most common questions with NCRs, and write statements that define the acceptable examples of objective evidence for these questions. These proposed compliance statements will then be presented at the next closed meeting. From this, further questions may be identified for the sub-team to work on. ACTION ITEM: Sub-team to write what is required to comply with checklist questions. Sub-team will work on the top five questions. Sub-team: Doug Matson, Mark Emerson, Jeff Thyssen, Sunder Rajan, Gerald Harvey. (DUE DATE: 28-Feb-2011) 31.0 PYROMETRY AND AUDIT HANDBOOKS UPDATES – CLOSED NUCAP Deviation 00021 – not agreed, non persuasive NUCAP Deviation 00022 – deviation rejected, but new wording agreed for clarification. 32.0 TABLED SUBJECTS – CLOSED None 11 HEAT TREATING OCTOBER 2010 33.0 NEW BUSINESS – CLOSED AMS2759 start of soak definitions need to be clarified in the Audit Handbook. It was agreed that Auditor Advisory HT-004 would be withdrawn until AMS2759 is re-issued. ACTION ITEM: Staff Engineers to withdraw Auditor Advisory HT-004. (DUE DATE: 28-Feb-2011). One ballot comment on AC7102/5 checklist was not understood. Staff Engineer to contact commenter and clarify what the concerns are. ACTION ITEM: Staff Engineers to obtain clarification of ballot comment. (DUE DATE: 28-Feb-2011). Heat Treating Task Group does not have a policy for Alternate Supplier Voting Members. This will be an agenda item for the February 2011 meeting. 34.0 RAIL / ACTIONS REVIEW – CLOSED See RAIL posted on www.eAuditNet.com/Documents/Heat Treat. ADJOURNMENT – (21-Oct-10) – Meeting was adjourned at 12:50 p.m. Minutes Prepared by: Jerry Aston - jerry.aston@pri-europe.org.uk ***** 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: NTGOP001 Appendix III Marcel Cuperman 12 Due date: 12/1/2010