COATINGS
OCTOBER 2014
CONFIRMED
CONFIRMED MINUTES
OCTOBER 20-23, 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, OCTOBER 20 TO THURSDAY, OCTOBER 23, 2014
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., 20-Oct-2014.
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
*
*
*
*
*
*
*
*
*
*
*
Nicolas
Fabrice
James
Ben
Masato
Patrick
Bjorn
Dan
Frank
Joel
Marc
Philippe
Udo
Yuki
Tetyana
Naoki
Jan
Hong Ping
(Holly)
COMPANY NAME
Barthelemy
Crabos
Dunn
Evans
Katagiri
Kiernan
Kjellman
Loveless
McManus
Mohnacky
Montreuil
Robin
Schuelke
Shinagawa
Shmyreva
Sogabe
Wigren
Zhao
Airbus Helicopters
SAFRAN Group
GE Aviation
Goodrich (UTAS)
Mitsubishi Heavy Industries
Rolls-Royce
GKN Aerospace Sweden AB
Parker Aerospace
Lockheed Martin Corporation
Hamilton Sundstrand (UTAS)
Heroux-Devtek
Airbus
Honeywell Aerospace
Mitsubishi Heavy Industries
Rolls-Royce
Mitsubishi Heavy Industries
GKN Aerospace Sweden AB
Bombardier, Inc.
Vice Chairperson
Chairperson
Other Members/Participants Present (* Indicates Voting Member)
NAME
*
*
Said
Paula
Phillip
Joshua
Jeffrey
Chris
Dale
Marty
Andrew
Paul
COMPANY NAME
Amegroud
Bartlett
Brockman
Crockett
Davis
Frederickson
Harmon
Hendricks
Mazzeo
Mravcak
Tecnickrome Aeronautique, Inc.
Oerlikon Metco (Canada), Inc.
Techmetals, Inc.
Ellison Surface Technologies
Hubbard-Hall, Inc.
Techmetals, Inc.
Cincinnati Thermal Spray
Ellison Surface Technologies
Paradigm Precision
Chromalloy
Secretary
COATINGS
OCTOBER 2014
CONFIRMED
*
*
*
*
Roger
John
Jinesh
Saroj
Steve
Bryan
Ronald
Vern
Jeffrey
Yoshihiro
Ng
Passmore
Patel
Patel
Payne
Roberts
Stewart
Talmadge
Tomczak
Tsuda
Oerlikon Metco (Canada), Inc.
St. Louis Metallizing
Southwest United Canada/CEEL Facility
JABIL
Praxair Surface Technologies
Heany Industries, Inc.
Ellison Surface Technologies
Howmet Thermatech Coatings
Techmetals, Inc.
IHI Corporation
PRI Staff Present
Jennifer
Jim
Bob
1.2
Kornrumpf
Lewis
Lizewski
Task Group Tutorial – OPEN
Udo Schuelke presented a tutorial explaining the functions of Nadcap and the CTTG, and showed
a video, narrated by Joe Pinto, on Antitrust to participants.
1.3
Review Agenda – OPEN
The agenda for the meeting was reviewed. No changes were proposed or made.
1.4
Expectations – OPEN
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: resolve Memorandum of Understanding (MOU) decision for
Grinding of Coatings; Cold Spray; Maintenance Repair Overhaul (MRO) terminology included in
checklist question guidelines.
1.5
Approval of Previous Meeting Minutes – OPEN
Motion made by Vern Talmadge and seconded by Ron Stewart to approve the minutes for the
June 2014 meeting held in Dublin, Ireland 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 and Bob Lizewski) met the criteria of over 10% audits
reviewed and greater than 90% concurrence. Delegation is maintained.
3.0
TASK GROUP RESOLUTION ITEMS – CLOSED
None
4.0
AUDITOR CONSISTENCY – CLOSED
The 2014 audit observation plan was reviewed. 5 of 10 observations planned in 2014 were
completed. Of the 5 observations that were not completed, 2 Subscriber Voting Members left the
Task Group, 2 were not scheduled, and 1 is scheduled for November.
The 2015 plan was developed using the list of audits scheduled from January 2015 through May.
6 observation audits were scheduled focusing on a new auditor joining Coatings (CT) in
COATINGS
OCTOBER 2014
CONFIRMED
November 2014 and Auditors that were not observed in 2014. The updated list is maintained in
the CTTG documents work area.
2 observation reports submitted after the June meeting were reviewed. Feedback was positive
and no rating of Does Not Meet was given.
Auditor consistency data was reviewed. The review included: individual Auditor evaluations and
Supplier feedback for all audits conducted between 1-May-2014 and 30-Aug-2014; peer
comparison of average number of NCRs written per audit day; influence of failure criteria on
written NCRs per audit; and the redline report that looks at the change in the number of NCRs at
the same facility performed by a different auditor. Supplier feedback comments were excellent.
There were no negative comments or suggestions for improvement.
Actions and suggestions taken as a result of reviewing auditor consistency data are as follows:
send an Auditor Advisory concerning NOP-007 requirement to not solicit Observer opinions
during the audit; separate cleaning and de-masking question in /2 and /4; revise solution control
sections in /4 and /6 to align with current Chemical Processing (CP) checklist; consider a PRI
repository of customer specifications to allow auditor access outside of the audit; post Auditor
feedback forms on forum for Subscriber review.
ACTION ITEM: Bob Lizewski to issue Auditor Advisory concerning NOP-007 requirement to not
solicit Observer opinions during the audit. (Due Date: 30-Nov-2014)
ACTION ITEM: Bob Lizewski to add rolling revision comments to AC7109/2 and /4 to separate
cleaning and de-masking questions and to AC7109/4 and /6 to align solution control sections with
the current CP checklist. (Due Date: 30-Nov-2014)
ACTION ITEM: Bob Lizewski to post Auditor feedback forms on eAuditNet/ CTTG work area/ forum
for Subscriber review. (Due Date: 31-Dec-2014)
Individual Auditor feedback was given by Bob Lizewski at the Auditor Conference. The feedback
was well received by the auditors. The CTTG agreed to continue the process in 2015.
Training was provided to both Auditors and CTTG Subscribers on the new Auditor communication
plan that utilizes the forum in CTTG documents work area. All were encouraged to begin using
the forum.
The CTTG approved the updated Auditor Consistency Work Instruction. The work instruction
defines the CTTG process for meeting NOP-012 requirements and is posted in the CTTG forum.
The October 2014 revision included: 4.3.2 new eAuditNet process for requesting observations
and completing observation feedback form; added eAuditNet communication forum and Auditor
feedback mechanism to 4.3.3.
5.0
MEMBERSHIP STATUS AND SUCCESSION PLANNING - OPEN
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. All current Voting Members have satisfied the requirements to maintain voting
membership.
Motion made to approve Hong Ping from Bombardier as a new Subscriber Voting Member.
Motion passed and member was confirmed by CTTG Chairperson Udo Schuelke.
Motion made to approve Philip Brockman from Techmetals as a new Supplier Voting Member.
Motion passed and member was confirmed by CTTG Chairperson Udo Schuelke.
COATINGS
OCTOBER 2014
CONFIRMED
A request for volunteers for the position of Alternate Vice Chairperson was made by Udo
Schuelke. No one volunteered for the position.
6.0
METRICS - OPEN
The NMC metrics through 30-Sep-2014 were presented by Udo Schuelke and Jennifer
Kornrumpf and reviewed by the Task Group.
Auditor Capacity Goal 130%: Green – 150% capacity projected through December 2014
On-Time Certifications Goal 98% on-time: Green – 100% one lapsed certs in June 2014
Supplier Merit Goal 80%: Green – 83% on merit as of September 2014.
Cycle Time (Initial) Jun14-Sep14, 12 audits
Total Goal 53 days: Green Jun, Jul, Aug (47, 35, 38) days, Yellow Sep (56) days
Staff Goal 17 days: Green all months (5, 5, 7, 11) days
Supplier Goal 28 days: Green Jun, Jul, Aug (30* prior goal, 16, 20) days, Red Sep (32)
days
Cycle Time (Reaccreditation Jun14-Sep14, 29 audits
Total Goal 53 days: Green all months (39, 39, 43, 38) days
Staff Goal 17 days: Green all months (16, 11, 7, 9) days
Supplier Goal 28 days: Green Jun, Jul, Sep (23, 21, 22) days, Red Aug (29) days
Bob Lizewski reviewed annual Auditor performance metrics for the period of 01-Oct-2013 through
30-Sep-2014. The review included Auditor evaluations, Supplier feedback and Auditor
consistency standard data. The overall Auditor rating was 5.82 for the period, representing 126
audits, and Supplier feedback was positive. The standard data showed an average of 1.3 NCRs
written per audit day for all audit types.
7.0
FIRST TIME SUPPLIER FEEDBACK – OPEN
One new supplier, Techmetals, provided feedback to the CTTG. Specifically, they asked the
CTTG to consider removing redundant questions on stripping in the core and AC7109/4
checklists and add PVD-Arc to the scope of AC7109/2. Overall, they found the tools made
available by the CTTG to be valuable during audit preparation. They also stated that the CT audit
improved their CP system as well.
8.0
NUCAP SCOPE EXCEPTIONS – OPEN
No NUCAP resolution items.
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
GRINDING OF COATING – OPEN
The CTTG discussed the issue of entering into a cross commodity agreement (MOU) with
Conventional Machining as a Special Process (CMSP) to include AC7126/5 into the CT scope.
The following information, compiled through RAIL items added in the June 2014 Nadcap meeting,
was incorporated into the discussion: number of AC7126/5 audits CMSP has conducted to date
(13); number of Suppliers affected by the mandate (10-20); willingness of CT auditors to perform
audit to AC7126/5 (unanimous Yes) and their grinding expertise (4 some experience, 3 quite a
bit).
COATINGS
OCTOBER 2014
CONFIRMED
Motion made by Ben Evans and seconded by Dan Loveless to enter into a cross commodity
agreement with Conventional Machining as a Special Process (CMSP) to include AC7126/5 into
the CT scope. Motion passed.
The CTTG reviewed the cross commodity agreement and decided on the following: CT will share
AC7126/5 with CMSP; CT will not participate in future document revisions. CT will be responsible
for CT auditor training; and performing audit reviews of AC7126/5 when the checklist is included
in a CT audit.
ACTION ITEM: Bob Lizewski to draft MOU agreement and send to CMSP for consideration. (Due
Date: 30-Nov-2014)
ACTION ITEM: Bob Lizewski to add an agenda item to the 2015 March CTTG Meeting to approve
the MOU agreement. (Due Date: 07-Nov-2014)
11.0
INDUSTRY STANDARD CHAMPION REPORT – OPEN
The Coatings Industry Standard watch list was reviewed. ASTM E 4-14 was revised in June
2014. Dan Loveless briefed the Task Group on the changes. No changes impact the audit
criteria.
The Coatings Industry Standard watch list was updated and posted to eAuditNet.
12.0
NOP-011 - OPEN
The CTTG has not participated in a risk mitigation activity to date.
13.0
AUDIT CRITERIA (CHECKLIST) REVISION – OPEN
Bob Lizewski briefed the Task Group on the AC7019/3 Rev F ballot that was issued due to the
inadvertent omission of the process gas section in AC7109/3 Rev E.
AC7109/5 Rev F ballot comments were resolved.
Motion made by Vern Talmadge and seconded by Steve Payne to remove questions 10.2.1.4 and
10.3.1 of AC7109/5. Voting Member Only vote called. Motion passed with 75% majority.
ACTION ITEM: Jennifer Kornrumpf to issue affirmation ballot for AC7109/5 Rev F Draft 2. (Due
Date: 14-Nov-2014)
Jan Wigren presented information on microscope magnification and resolution indicating that
objective numeric aperture is a key factor. The discussion was a continuation of the topic of
magnification when using digital imaging systems from the June meeting. The presentation will be
posted on eAuditNet.
Revisions to AC7109/1 Rev D continued.
14.0
2014 AUDITOR CONFERENCE – OPEN
Bob Lizewski summarized the activities of the 2014 Auditor Conference. Topics included recent
checklist revisions AC7109/3E and AC7109/7D; individual feedback provided to Auditors;
technical brief on coating composition analysis; NOP-012 communication plan (Auditor forum);
NCR metrics; and effective audit preparation including the job tracker.
The CTTG provided the following guidance on issues raised in the open discussion: the number
of significant figures defined for a given parameter must be considered when reading an analog
gage and determining if the parameter is within tolerance; violations of a GE Aviation ‘S’
specification (e.g., S459) are not to be considered as having potential impact on hardware; tests
covered by AC7109/5E include only those tests performed in the lab (this will change in
COATINGS
OCTOBER 2014
CONFIRMED
AC7109/5F); powder feed rate fluctuations measured in real time that are outside of tolerance
limits constitute an NCR, however, it is acceptable to define the real time feedrate as for
reference only if there is another defined method used to establish feed rate; and requirements in
approved work instructions cannot supersede requirements in a higher level document (Purchase
Order, Drawing, Specification) unless the higher level document specifically states it is
acceptable.
ACTION ITEM: Bob Lizewski to add the guidance provided by the CTTG during the Auditor
Conference to the CTTG Audit Handbook. (Due Date: 31-Jan-2015)
ACTION ITEM: Steve Payne to raise the issue of document hierarchy to SSC in order to elevate the
discussion and obtain a consistent statement/policy on document hierarchy across Nadcap. (Due
Date: 28-Feb-2015)
15.0
NCR ANALYSIS – OPEN
Bob Lizewski presented data of the top NCRs issued by checklist for the period October 1, 2013
through September 30, 2014. The data is posted in the Top NCR report located on eAuditNet
CTTG public documents.
In addition the frozen process violation report was presented with updated data from audits
conducted in 2011, 2012 and 2013. This report is also posted on eAuditNet CTTG public
documents.
The CTTG reviewed data on NCR paragraph references by auditor covering 115 audits in 2013
and 2014. Checklist AC7109D had an even distribution of paragraph citings among auditors with
citings increasing in the areas of fixed process control, test material and specimen id, and
stripping method not being defined. Paragraph references for AC7109/1C decreased compared
to prior periods particularly in profilometry and Appendix A parameters being defined in work
instructions; however, violations to defined parameters continues to be a trouble spot. For
AC7109/5E, the number of citings overall has decreased from prior periods, but trouble spots are
still evident in sample preparation and bend testing.
16.0
CONTINUOUS IMPROVEMENT INITIATIVE – OPEN
The CTTG Subteam (Patrick Kiernan, Dan Loveless, and Ron Stewart) reported out on activities
supporting the Continuous Improvement Project: Auditor Evaluation Form. The form was
implemented at the Auditor Conference and was well received.
The CTTG Subteam (Jan Wigren, Dale Harmon, Joel Mohnacky, Ben Evans, and Francis
Monerie-Moulin) reported out on activities supporting the Continuous Improvement Project:
Glossary of Terms. Each team member was assigned a checklist and tasked to extract terms.
The terms will be cross referenced and the list pared down to create a set of common terms.
Each common term will then be defined. Expected completion date is June 2015. Auditor
Francesco Siniscalchi was added as a member of the Subteam.
Two new Continuous Improvement Project ideas were added (Guidance for Suppliers/Auditors on
using the job tracker (Expectations/Planning) and review Coatings Industry Standards and
provide suggested changes to Committee B (AMS 2437, 2447, 2448, 2444) to the continuous
improvement projects list. A new project was not selected at this meeting and will be deferred
until March.
17.0
REVIEW GUIDELINES FOR RESPONDING TO NCRS – OPEN
The CTTG Guidelines for responding to audit findings was updated to add an example for
inadequate specification review. The guidelines are posted in eAuditNet CTTG public documents.
COATINGS
OCTOBER 2014
CONFIRMED
18.0
ANNUAL PROGRAM DOCUMENT REVIEW
Document owners are required to review all program documents at a minimum biennially. All
CTTG documents have been reviewed and revised in 2014 with the exception of NIP 6-01
Appendix CT. NIP 6-01 Appendix CT was revised significantly in 2012 to improve auditor training.
The CTTG reviewed the document and concurred that the process is working well and no
changes are required.
ACTION ITEM: Bob Lizewski to process an editorial change to NIP 6-01 Appendix CT adding
Biennial review – no changes in the revision history table. (Due Date: 7-Nov-2014)
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.
ACTION ITEM: Dale Harmon will discuss with SSC leadership team if data is being collected on
audit results for those Suppliers being mentored versus those who are not mentored. (Due Date:
7-Nov-2014)
20.0
NMC, AQS AND PLANNING & OPS REPORT – OPEN
Vern Talmadge 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.
Subscribers performing observation audits are being asked to also observe the AQS portion if it is
part of the audit being observed.
Vice Chairperson Joel Mohnacky and Staff Engineer Bob Lizewski briefed the CTTG on items of
interest from the Planning and Ops meeting. Major discussion topics were: Task Group reports;
NOP-012 Auditor Consistency; and observation audit data (number of observations canceled and
number of reports not submitted).
21.0
NEW BUSINESS – OPEN
Suspension spraying as a new technology was discussed. It uses standard plasma and HVOF
guns but has a modified powder delivery method. The process is under development currently by
some CTTG Subscribers, but there are no specifications or requirements. The CTTG agreed to
take no action at this time, but keep the process under observation.
Cold spray was raised again as a potential, new technology. Honeywell has developed
requirements for internal Maintenance Repair and Overhaul applications. If there is interest from
other CTTG Subscribers, questions could be developed for the process and added to AC7109/1.
ACTION ITEM: CTTG Subscribers to report out at the March 2015 CTTG meeting on their
company’s interest in adding Cold Spray as a process under AC7109/1. (Due Date: 28-Feb-2015)
Subscriber methods for defining frozen processes was discussed. A comment was made that
many frozen process violations are not significant to the process or audit, and cause valueless
additional time to resolve by Subscribers and Suppliers. A request was made of Subscribers to
review their internal frozen process policy and consider including only critical process parameters
as part of the frozen process.
The issue of the CTTG liaising with SAE Committee B and providing input on standards such as
AMS2444, AMS2447 and AMS2448 was raised. Subscribers and Suppliers agreed that CTTG
input could be valuable and lead to broader use of the industry standards.
COATINGS
OCTOBER 2014
CONFIRMED
ACTION ITEM: Bob Lizewski to find out information on SAE Committee B [when they meet,
leadership, revision cycle etc.] and explore opportunities for CTTG participation. (Due Date: 31Jan-2015)
An inquiry about Pratt and Whitney representation on the CTTG was raised. Bob Lizewski will
follow-up with Dave Soong (Pratt and Whitney NMC representative) about their plans for
providing someone to participate in the CTTG.
22.0
MEETING CONCLUSION – OPEN
22.1
Review Expectations
All expressed expectations for this meeting were met.
22.2
Agenda Items for Next Meeting
Next meeting will be March 2-5, 2015 in Berlin, Germany. Proposed agenda items beyond the
standard items include: resolution of AC7109/5F ballot comments; AC7109/1 revision;
incorporation of Cold Spray as a process in AC7109/1; Cross Commodity agreement with CMSP
on AC7126/5; CI Project update [Glossary of terms]; NOP-011 Risk Mitigation (RM) (feedback on
RM process); identify Alternate Vice Chair; SAE Committee B discussion.
22.3
New Action Items
New action items were documented by CTTG Secretary Dale Harmon. For details see the
Coatings Action Item List (RAIL) posted at www.eAuditNet.com.
22.4
Meeting Feedback
Meeting feedback was positive. The CTTG expressed gratitude to staff engineer Bob Lizewski for
his years of excellence service.
ADJOURNMENT – 24-Oct-2014 – Motion made by Vern Talmadge and seconded by Joel Mohnacky to
adjourn the meeting at 11:00 a.m. Motion passed.
Minutes Prepared by: Dale Harmon dharmon@cts-inc.net
Bob Lizewski blizewski@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:
Coatings Audit Handbook
Bob Lizewski
AC7109/5 Rev F
Jennifer Kornrumpf
MOU with CMSP for AC7126/5
Bob Lizewski
NIP 6-01 Appendix CT
Bob Lizewski
Due date:
31-Jan-2015
14-Nov-2014
30-Nov-2014
07-Nov-2014