COATINGS
OCTOBER 2015
UNCONFIRMED
UNCONFIRMED MINUTES
OCTOBER 19-22, 2015
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 19 TO THURSDAY, OCTOBER 22, 2015
1.0
OPENING COMMENTS
1.1
Call to Order / Quorum Check
The Coatings Task Group (CTTG) was called to order at 8:00 a.m., 19-Oct-2015.
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
*
*
*
*
*
*
*
*
*
Mark
Fabrice
James
Patrick
Bjorn
Dennis
Joel
Josefa
Carlos
Udo
Tetyana
Xiaohang “Mike”
Yuichi
Jeffrey
Stanley
Kara
Hong
COMPANY NAME
Binfield
Crabos
Dunn
Kiernan
Kjellman
Meehan
Mohnacky
Rodriguez Baena
Sanchez Bautista
Schuelke
Shmyreva
Song
Sugiyama
Torone
Trull
Warrensford
Xia
UTC Aerospace (Goodrich)
SAFRAN Group
GE Aviation
Rolls-Royce
GKN Aerospace Sweden AB
Pratt & Whitney
UTC Aerospace (Hamilton Sundstrand)
Airbus Defense & Space
Airbus Helicopters
Honeywell Aerospace
Rolls-Royce
Sikorsky Aircraft Corporation
Mitsubishi Heavy Industries, Ltd.
Triumph Engine Controls
Honeywell Aerospace
Honeywell Aerospace
Rolls-Royce
Other Members/Participants Present (* Indicates Voting Member)
NAME
*
*
Paula
Phillip
Francisco
Christopher
Dale
Marty
Kazuhiko
Masato
Alexander
Mark
Nobuyoshi
Nuyeli
COMPANY NAME
Bartlett
Brockman
Contreras
Gastelum
Fredrickson
Harmon
Hendricks
Kakinuwa
Katagiri
Klyuch
Mooloey
Mori
Izaguirre
Oerlikon Metco (Canada), Inc.
Techmetals, Inc.
Ellison Surface Technologies
Techmetals, Inc.
Cincinnati Thermal Spray
Ellison Surface Technologies
IHI
Mitsubishi Heavy Industries, Ltd.
Blades Technology, Ltd.
Techmetals, Inc.
IHI
LMI Aerospace - Mexicalli
COATINGS
OCTOBER 2015
UNCONFIRMED
*
*
*
*
Joe
Brynn-Marie
Steve
Bryan
Ronald
Vern
Jeffrey
Martha
Yoshihiro
Olah
O’Neil
Payne
Roberts
Stewart
Talmadge
Tomczak
Tress
Tsuda
Cincinnati Thermal Spray
Ellison Surface Technologies
Praxair Surface Technologies
Heany Indutries, Inc.
Ellison Surface Technologies
Howmet Thermatech Coatings
Techmetals, Inc.
SAE
IHI
PRI Staff Present
Jennifer
Mike
Justin
1.2
Kornrumpf
Ploucha
Rausch
Safety Information – OPEN/CLOSED
Safety information for the meeting, including the crisis and evacuation plans for the hotel, was
reviewed.
1.3
Review Code of Ethics and Meeting Conduct – OPEN/CLOSED
Justin Rausch presented a tutorial explaining the functions of Nadcap and the CTTG, and
reviewed the Nadcap Code of Ethics.
1.4
Present the Antitrust Video – OPEN/CLOSED
Justin Rausch showed a video, narrated by Joe Pinto, on Antitrust to participants.
1.5
Review Agenda – OPEN/CLOSED
The agenda for the meeting was reviewed. No changes were proposed or made.
1.6
Expectations – OPEN/CLOSED
Attendees were given the opportunity to identify expectations to be addressed during the week of
meetings. A list was started in the closed meeting and reviewed again in the open meeting.
Expectations beyond agenda items: Make NCR data available quickly, revisit Continuous
Improvement Project List, follow established guidelines for audit criteria revision.
1.7
Acceptance of Meeting Minutes – OPEN
Motion made by Vern Talmadge and seconded by Steve Payne to approve the minutes for the
June 2015 meeting held in Montreal, Canada without change. Motion passed.
2.0
REVIEW DELEGATION STATUS – CLOSED
Data was reviewed for CTTG Subscriber concurrence with audit report reviewer decisions. The
delegated audit report reviewers (Jim Lewis, Bob Lizewski, and Justin Rausch) met the criteria of
over 10% audits reviewed and greater than 90% concurrence. Their delegation is maintained. A
delegation status change occurred during the review period, and one audit report reviewer (Justin
Rausch) was not yet delegated for a portion of the audits reviewed. This audit report reviewer met
the criteria of 100% oversight and greater than 90% concurrence on those audits.
3.0
TASK GROUP RESOLUTION ITEMS – CLOSED
Review of Audit 162726, NCR 3 – the Auditee requested Task Group resolution to determine if an
illegible photograph in work instructions is a valid finding. The image resolution of a photo was
lost due to the technical plan being photocopied. The CTTG determined that this was a valid NCR
COATINGS
OCTOBER 2015
UNCONFIRMED
because the photo is referenced within the work instructions as a supporting material to
determine if the part is contaminated and needs further demasking.
Review of Audit 170042, NCR 22 and Observation 2 – The Staff Engineer requested Task Group
resolution to determine if a portable PAT tensile test machine is an acceptable piece of
equipment within the CTTG requirements. The manufacturer’s brochure indicates the equipment
meets ASTM C633 requirements for tensile testing. The CTTG determined that there currently is
not enough evidence to support this machines validity. Until additional evidence is provided that
the PAT tensile test machine produces repeatable and comparable tensile results, it is not an
unacceptable replacement for standard tensile equipment.
ACTION ITEM: Justin Rausch to issue an Auditor Advisory discussing the CTTG’s decision on the
portable PAT tensile test machine. (Due Date: 31-Dec-2015).
Review of Audit 166830 – The Staff Engineer requested Task Group resolution to determine how
the scope of AC7109/5 should be identified if the sample preparation for a tensile test is
performed on-site but the actual test is outsourced. The CTTG’s expectation is for both the
sample preparation and actual testing to be performed by the same facility.
ACTION ITEM: Justin Rausch to issue an Auditor Advisory about sample preparation being
performed by the same facility that performs the actual test. (Due Date: 31-Dec-2015).
4.0
AUDITOR CONSISTENCY – CLOSED
4.1
Review Observation Plan
The 2015 audit observation plan was reviewed. Three of five candidates for observation for 2015
have been observed to date. Of the two candidates who were not observed, one chose to leave
the CTTG (and PRI) as an auditor, and an observation is planned for the other auditor. Beyond
the candidates for observation plan, two additional observations have been performed in 2015,
with another two scheduled.
Two observation reports submitted after the June meeting were reviewed. Feedback was positive
and no rating of ‘Does Not Meet’ was given.
4.2
Review Auditor Consistency Data
Auditor consistency data was reviewed. The review included: individual Auditor evaluations and
Supplier feedback for all audits conducted between 1-May-2015 and 31-Aug-2015; peer
comparison of average number of NCRs written per audit day; and influence of failure criteria on
written NCRs per audit; Supplier feedback comments were excellent. There were no negative
comments or suggestions for improvement.
As a result of reviewing auditor consistency data, no further actions are needed at this time.
4.3
Review Dashboard Metrics
The Coatings dashboard metrics through 30-Sep-2015 were presented by Justin Rausch and
reviewed by the Task Group.
Checklist Revisions Resulting from Auditor Feedback, Goal None: Green – 7 changes made
due to auditor feedback in AC7109/1 Rev D.
Frequency of Auditor Consistency Data Review, Goal Annually: Green – On the October 2015
meeting agenda (Reviewed every meeting).
New Auditor Training, Goal 95%: Green – 100% 15 of 15 auditors answered “Yes” that the New
Auditor Training was effective since Oct 2014. Three of three CT auditors stated that the CT
specific training was effective.
COATINGS
OCTOBER 2015
UNCONFIRMED
Supplier Feedback Question 15, Goal 100%: Yellow – 98% Suppliers answered “Yes” that the
auditor was consistent compared to previous auditors for 42 of 43 audits. One supplier answered
“No” because an NCR was written against a process that had been audited on previous audits.
The NCR was a valid finding.
5.0
MEMBERSHIP AND SUCCESSION PLANNING – OPEN
5.1
Current Voting Member Participation [Meeting and Ballots]
The voting records and meeting attendance for CTTG Voting Members (Subscriber and Supplier)
were reviewed for compliance to the requirements for maintaining membership. The requirements
state that to maintain membership a member must not be absent without approved alternate
representation from three consecutive regular Nadcap Task Group meetings and the member, or
approved alternate representation, shall not miss a vote on more than 2 consecutive letter ballots.
The Task Group Chairperson is allowed to waive these requirements if other circumstances
warrant retention. Udo Schuelke, Jack Saunders, Ben Evans, and Nicolas Barthelemy missed at
least two consecutive ballots.
Motion made to maintain Udo Schuelke and Jack Saunders from Honeywell as a Subscriber
Voting Member and a Subscriber Alternate Voting Member, respectively. Motion passed.
No motion was made for Ben Evans from UTC Aerospace (Goodrich) and Nicolas Barthelemy
from Airbus Helicopter as representatives from the respective companies indicated that neither
would continue to support of the CTTG. Additionally, Voting Members from Rolls Royce indicated
that Tim Pruitt from Rolls Royce Corp will no longer be participating in the CTTG.
Vice Chairperson Joel Mohnacky approved maintaining voting membership for Udo Schuelke and
Jack Saunders.
5.2
New Voting Members
Motion made to approve Carlos Sanchez Bautista from Airbus Helicopters as a new Subscriber
Voting Member (UVM). Motion passed and member was confirmed by CTTG Chairperson Udo
Schuelke.
Motion made to approve Mark Binfield from UTC Aerospace (Goodrich) as a new Subscriber
Voting Member (UVM). Motion passed and member was confirmed by CTTG Chairperson Udo
Schuelke.
5.3
Succession Plan
The current CTTG succession plan was reviewed with Udo Schuelke as the Chairperson, Joel
Mohnacky as the Vice-Chairperson, and Dan Loveless is the Alternate Vice-Chairperson.
Björn Kjellman from GKN Aerospace Sweden AB has volunteered for the position of Second
Alternative Vice-Chairperson.
6.0
METRICS – OPEN
6.1
NMC
The NMC metrics through 30-Sep-2015 were presented by Justin Rausch and reviewed by the
Task Group.
Auditor Capacity, Goal 130%: Green – 167% capacity projected through December 2015.
On-Time Certifications, Goal 98% on-time: Green – 100% no lapsed cert through September
2015.
Supplier Merit, Goal 80%: Yellow – 79% on merit as of September 2015.
COATINGS
OCTOBER 2015
UNCONFIRMED
Cycle Time (Initial) Jun 2015-Sep 2015, 3 audit
Total, Goal 53 days: Yellow Aug (55) days, No initials in Jun, Jul, Sep.
Staff, Goal 17 days: Green Aug (12) days, No initials in Jun, Jul, Sep.
Supplier, Goal 28 days: Red Aug (31) days, No initials in Jun, Jul, Sep.
Cycle Time (Reaccreditation Feb 2015-May 2015, 38 audits
Total, Goal 53 days: Green Jun, Jul, Aug (42, 43, 42) days. Yellow Sep (56) days.
Staff, Goal 17 days: Green all months (6, 5, 7, 10) days.
Supplier, Goal 28 days: Green Jun, Jul, Aug (24, 24, 23) days. Red Sep (32) days
7.0
FIRST TIME SUPPLIER FEEDBACK – OPEN
No first time Suppliers were in attendance.
8.0
NUCAP SCOPE EXCEPTION RESOLUTIONS – OPEN
No NUCAP resolution items were discussed.
9.0
RAIL (ROLLING ACTION ITEM LIST) – OPEN
The Rolling Action Item List (RAIL) was reviewed.
For specific details on all RAIL items, please see the current Coatings Rolling Action Item List
posted at www.eAuditNet.com, under Public Documents.
10.0
INDUSTRY STANDARD CHAMPION REPORT – OPEN
The Coatings Industry Standard watch list was reviewed. Fabrice Crabos and Björn Kjellman
discussed changes to ISO 6508-1, -2, and -3 made in March 2015. These changes do not require
revision to AC7109/5. No other revision changes have been made to the relevant standards.
11.0
NCR ANALYSIS – OPEN
11.1
Top 10 NCRs for 2014/2015
Justin Rausch presented data of the top NCRs issued by checklist for the period 1-Oct-2014
through 30-Sep-2015. Calibration was highlighted as a common issue across all checklists.
ACTION ITEM: Justin Rausch to discuss a potential calibration course with staff from eQuaLearn.
(Due Date: 29-Jan-2016)
11.2
NCR Paragraph Reference by Auditor Report for 2014/2015
The CTTG reviewed data on NCR paragraph references by auditor covering 138 audits from
1-Oct-2014 through 30-Sep-2015. This review included Checklists AC7109 Rev D, AC7109/1 Rev
C, and AC7109/5 Revs E and F.
In addition, the frozen process violation report was presented with updated data from audits
conducted in from 1-Oct-2014 through 30-Sep-2015.
ACTION ITEM: Jennifer Kornrumpf to post the Top NCR, NCR Paragraph Reference, and Frozen
Process Violation Reports to eAuditNet. (Due Date: 06-Nov-2015)
COATINGS
OCTOBER 2015
UNCONFIRMED
12.0
ANNUAL PROGRAM DOCUMENT REVIEW – OPEN
Document owners are required to review documents at a minimum biennially. All CTTG
documents have been reviewed and revised in 2015. The recent updates to OP 1114 App CT
and 1116 App CT were briefly discussed.
13.0
AUDIT CRITERIA (CHECKLIST) REVISION – OPEN
13.1
AC7109 Rev E
Ballot comments to AC7109 were resolved. This checklist is ready for affirmation ballot.
13.2
AC7109/8 Rev NA
Ballot comments to AC7109/8 were resolved. The original ballot did not receive the required
number of approval votes. So, the checklist will be submitted for a second letter ballot.
13.3
AC7109/4 Rev D
Revisions to AC7109/4 Rev D were started. This checklist was completed and is ready for ballot.
13.4
AC7109/2 Rev D
Revisions to AC7109/2 Rev D were started. This revision will continue at the February 2016
meeting.
ACTION ITEM: Sub-team (Jeff Tomczak, Udo Schuelke, Mark Binfield, Jim Dunn, and Jan Refsdal)
to develop an appendix of process parameters to supplement AC7109/2 Rev D. (Due Date: 22-Feb2016)
14.0
CONTINUOUS IMPROVEMENT INITIATIVE – OPEN
14.1
Glossary of Terms Project Update
The CTTG sub-team (Jan Wigren, Dale Harmon, Joel Mohnacky, and Francis Monerie-Moulin)
reported out on activities supporting the Continuous Improvement Project: Glossary of Terms.
The sub-team has identified terms that need to be defined as part of the glossary. Additionally, a
list of preferred terms was compiled. The team will begin to provide definitions for the identified
terms.
ACTION ITEM: Dennis Meehan to provide Pratt and Whitney’s technical glossary for reference if
permitted. (Due Date: 20-Nov-2015)
14.2
Review Project List
The Continuous Improvement Projects list was reviewed and updated to reflect several projects
that have been addressed outside of the Continuous Improvement sub-team format.
ACTION ITEM: Jim Dunn to research NCR data collection within eAuditNet with respect to
effective categorization of NCRs. (Due Date: 22-Feb-2016)
14.3
Develop New Project Charter
The next Continuous Improvement Project was selected (Technical Briefing Topic List) and the
project charter completed. A sub-team was formed to work on the project and report out at the
February 2016 meeting in Madrid.
ACTION ITEM: Sub-team (Fabrice Crabos, Patrick Kiernan, Steve Payne, and Vern Talmadge) to
develop a list of potential technical briefing topics for future Auditor Conference training. (Due
Date: 22-Feb-2016)
COATINGS
OCTOBER 2015
UNCONFIRMED
15.0
2015 AUDITOR CONFERENCE
Justin Rausch summarized the activities of the 2015 Auditor Conference. Topics included recent
checklist revisions AC7109/1 Rev D; individual feedback provided to Auditors; an introduction to
AC7109/8; technical training on grinding of coatings; Audit Effectiveness feedback; NCR metrics;
customer specification discussion; and the Candidates for Observation Plan.
The CTTG provided the following guidance on issues raised in the open discussion: When a gas
or material certification is verified against requirements, the date of the review does not need to
be listed on the certification; sampling plans must include both sampling of manufacturing lots for
engineering tests and sampling inspection of characteristics generated; operator approval/reapproval records are to link to a test, but the re-approval record does not need to be a practical
test; and laboratory furnaces must have a time and temperature recorder, but the load
thermocouple does not needed to be attached to the recorder (the load thermocouple must be
monitored, but other means of monitoring are allowed).
16.0
OP 1110 AND RISK MITIGATION PROCESS – OPEN
Justin Rausch presented some of the changes to the Risk Mitigation process that are being
proposed to the NMC.
17.0
NMC OUTSOURCED PYROMETRY SUB-TEAM REPORT OUT – OPEN
Joel Mohnacky updated the CTTG on the activities of the NMC Outsourced Pyrometry sub-team.
The sub-team proposed that eQuaLified exams could be used as a resource to evaluate
Outsourced Pyrometry sources.
18.0
NMC AUDITEES WITHOUT NADCAP CUSTOMERS SUB-TEAM REPORT OUT – OPEN
Udo Schuelke reported that no action has been taken by this sub-team yet.
19.0
SSC REPORT – OPEN
Dale Harmon (Cincinnati Thermal Spray), Coatings representative to the Supplier Support
Committee (SSC), presented an overview of the SSC and items of interest from the SSC
meeting. For complete details, see published minutes of the SSC posted on www.p-r-i.org.
20.0
NMC, AQS, AND PLANNING & OPS REPORT – OPEN
Dale Harmon updated the CTTG on items of interest from the Nadcap Management Council
(NMC). For complete details, see published minutes of the NMC posted on www.p-r-i.org.
Joel Mohnacky reported out on the Aerospace Quality Systems (AQS) liaison meeting. AQS has
offered to review checklist for QMS redundancy. A calibration sticker need not be attached
directly to the device but can be in close proximity if clearly labeled.
Chairperson Udo Schuelke briefed the CTTG on items of interest from the Planning and Ops
meeting. Major discussion topics were: Audit effectiveness; the Risk Mitigation Process proposal;
and the Nadcap satellite facility definition.
21.0
NEW BUSINESS – OPEN
No new business was presented.
22.0
MEETING CONCLUSION – OPEN
22.1
Review Expectations
All expressed expectations for this meeting were met.
COATINGS
OCTOBER 2015
UNCONFIRMED
22.2
Agenda Items for Next Meeting
The next meeting will be February 22-25, 2016 in Madrid, Spain. Proposed agenda items beyond
the standard items include: Ballot comment resolution for AC7109/4 Rev D and AC7109/8 Rev
NA; continuation of AC7109/2 Rev D; start of AC7109/6 Rev D; Continuous Improvement
Glossary of Terms and Technical Briefing Project List sub-team report outs; technical briefing
example presentation and template creation; SSC introduction presentation; open discussion on
new technologies; and determination of whether AC7102 is a suitable replacement for AC7109/7.
22.3
Review New Action Items
New action items were documented by CTTG Secretary Dale Harmon. For details, see the
Coatings Rolling Action Item List (RAIL) posted at www.eAuditNet.com.
22.4
Meeting Feedback
Meeting feedback was positive. Concerns were expressed over the meeting room shape and
climate control.
ADJOURNMENT – 22-Oct-2015 – Motion made by Jim Dunn and seconded by Dale Harmon to adjourn
the meeting at 11:00 a.m. Motion passed.
Minutes Prepared by: Dale Harmon dharmon@cts-inc.net
Justin Rausch jrausch@p-r-i.org
RAIL: See www.eAuditNet.com/Public Documents/Coatings
***** 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:
Due date: