The Nadcap Process

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The Nadcap Process
Julio Perez Head of Supplier Approval and
External Bodies Airbus SAS April 19, 2004
http//www.pri-network.org
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Industry Managed
Audit Standard Checklist
Industry experts manage all key steps
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Nadcap - Industry Working Together
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Relationship between AS, AC, Auditor Handbook and
Prime Requirements
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Nadcap Special Process Commodities

• NDT (AS7114)
• Heat Treating (AS7102)
• Materials Testing (AS7101)
• Chemical Processing (AS7108)
• Coatings (AS7109)
• Welding (AS7110)
• NMSE (AS7116 AS7117)

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Non Destructive Testing

• Liquid Penetrant
• Magnetic Particle
• Ultrasonics
• Radiography

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Heat Treating

• Alloy Families Aluminum, Beryllium/Copper,
  Copper, Cast Irons, Nickel and Cobalt, Magnesium,
  Stainless/pH Stainless Steels, Steels, Titanium
• Processes Carburizing, Nitriding, Carbo-
  Nitriding, Hardening Tempering, Ferritic
  Nitrocarburizing, Ion Nitriding, Vacuum Heat
  Treating, Vacuum Oil Quenching, Induction
  Hardening, Furnace Brazing, Dip Brazing,
  Induction Brazing, Hot Forming/Hot Sizing, Flame
  Hardening, Cryogenic Treatments, Die Quenching,
  Hipping
• Testing (In-Support of Heat Treatment)
  Metallography, Hardness, and Tensile Testing
  (Room-Temperature)

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Materials Testing Laboratories

• Chemical Laboratories
• Mechanical Laboratories
• Metallography and Microhardness
• Hardness
• Corrosion and Oxidation
• Mechanical Test Specimen Preparation
• Differential Thermal Analysis
• Heat Treating of Specimens
• Fastener Testing

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Chemical Processing

• Plating
• Anodizing
• Conversion/Phosphate Coatings
• Paints and Solid Film Lubricants
• Other Processes Passivation, Titanium
  Cleaning/Etching, Brush Plating, Chemical
  Milling, Etching

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Coatings

• Thermal Spray
• Vapor Deposition
• Cementation
• Stripping
• Coating Evaluation
• Plating of Coated Parts

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Welding

• Torch/Induction Brazing
• Flash Welding
• Electron Beam Welding
• Resistance Welding
• Fusion Welding
• Laser Welding
• Friction/Inertia Welding
• Diffusion Welding
• Percussion Stud Welding
• Foundry In-Process Welding of Castings
• Gas Tungsten Arc Fusion Spot

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Nonconventional Machining and
Surface Enhancement

• Electrochemical Machining
• Electrochemical Grinding
• Electrical Discharge Machining
• Laser Beam Machining
• Shot Peening

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Industry Managed
Audit Standard Checklist
Auditor Qualification Selection
Industry experts manage all key steps
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Auditor Selection/Interview/Performance

• Established Core and Technical Requirements
• Interview
• Testing/Certification (Optional)
• Training
• Review of Training with Report from Lead Auditor
• Approval by Task Group
• Continual Monitoring through Audit Reviews
• Annual PRI/Nadcap Training

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Sample of Current Auditors Experience
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Sample of Current Auditors Experience
(continued)
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Industry Managed
Audit Standard Checklist
Auditor Qualification Selection
Audits Conducted
Industry experts manage all key steps
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Audit Process

• PRI/Suppliers Schedules the Audit On-Line
• Checklists and Preparation Instructions available
  on eAuditNet
• Request for Self-Audit
• Auditor Conducts the Audit
• Pre-Audit and Post-Audit Interviews
• Requests responses to Findings within 21 calendar
  days
• Auditor Prepares Letter and attaches to audit
  report
• Audit Reports are submitted to PRI Staff for
  Review electronically

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Audit Content

• Quality Systems
• Special Process Specific Requirements
• Compliance/Job Audits
• NDT 3 Compliance Jobs per Method
• Heat Treating 2 Long Jobs-8 Short Jobs
• Materials Lab Witnessing of All Test Methods
• Chemical Processing Four Job Audits
• Coatings 5 Job Audits (Based on Scope)
• Welding 2 Job Audits per Method
• NMSE 2-8 Job Audits

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Industry Managed
Audit Standard Checklist
Auditor Qualification Selection
Corrective Actions As Required
Audits Conducted
Audit Results
Industry experts manage all key steps
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NCR Classifications
Major Nonconformance Any nonconformance that
could - adversely affect safety as related to
products, persons or property - impact the
usability of a product, performance of a service,
or the integrity of the quality system -
significantly increase product cost -
potentially affect the ability to meet the
customers requirements. Examples incorrect
process parameters, missing inspections or
processing steps, failure to record required
data, missed or out-of-tolerance calibration -
result from failure to implement a corrective
action from the previous audit. Minor
Nonconformance Any non-systemic, isolated
nonconformance that does not - adversely affect
the usability of a product, performance of a
service, or the integrity of the quality
system - affect any product or process output.
Example paperwork oversights, minor changes to
procedures for clarification.
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Submittal of Objective Evidence
- For initial audits, the suppliers shall
submit objective evidence of implementation for
all corrective actions. - For reaccreditation
audits, all Major NCRs, including any finding
having product impact or any finding that results
from failure to implement corrective action from
a previous audit, require objective evidence of
implementation. Minor NCRs shall not require
submittal of objective evidence. For Minor NCRs,
the corrective action response submitted by the
supplier shall identify the specific actions
taken to resolve the nonconformance(s), (e.g.,
exact text of procedure change, text of stamp to
be ordered, etc.)
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NOP-009

• Early Review Procedure (05-NOV-03)
• SE Early Review within 3 Days of Receipt of audit
  results
• Forwarded to User Members within 48 Hours
• User Members have five business days to respond

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NOP-010

• Supplier Escape Reporting (05-NOV-03)
• Escapes must be reported by Nadcap Accredited
  Suppliers (may also be reported by Users/Tier One
  Suppliers)
• Reported via www.aeroescape.com
• Monthly report generated by PRI and forwarded to
  NMC User Members and NESPB

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NOP-011

• Audit Failure Process (05-NOV-03)
• Five Failure Modes
• A Supplier Stops Audit
• B Excessive Number of Findings
• C Severity of Findings
• D Too Many Review Cycles to Complete
• E Non-Responsiveness by Supplier
• (All Task Group Specifics defined in Appendix A)

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NOP-011 Continued

• Audit Failure Process (05-NOV-03)
• All Audit Failures require Supplier Advisory
• A,E are Informational
• B,C,D Levels Determined by Task Group
• Audit Classified in eAuditNet as Failed
• Supplier provided formal notification detailing
  re-entry requirements
• Minimum of 3 months before another audit is
  conducted
• Initial Audit Classification
• Corrective Action Demonstration to Auditor

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Supplier AdvisoriesSources PRI Auditors/Staff,
OEMs/Primes/Government, Suppliers, Publications
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PRI Staff Review

• Staff Reviews Package for Completeness
• All Questions Answered, N/As explained,
  Attachments noted, Nonconformances correctly
  completed
• Review Audit Report
• Clarification Changes (electronically) - Contact
  Auditors for Clarification
• Review Supplier Corrective Action
• Close-Out or request additional information via
  Forums
• Audit Report Package is submitted electronically
  for Task Group Review

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Task Group Review

• Task Group decides Procedure for Review
• Sub-group review, entire Task Group Review
• Task Group Reviews for Correctness
• Technical Comments, Supplier Responses, Technical
  Completeness, Auditor Summary Letter, Identify
  Additional Findings
• Completes Review of Each NCR and dispositions
  (NCR Status)
• Discuss Results with Task Group within Forums
• Task Group Votes on Accreditation via On-Line
  Balloting

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Nadcap - Industry Working Together
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Nadcap eAuditNet Process
Suppliers
PRI Audit Scheduled
Auditor Assigned
Request Audit
Task Group Approval
Audit Completed
PRI Technical Staff Review
Issue Cert
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Industry Managed
Audit Standard Checklist
Process Evaluation/ Improvement
Auditor Qualification Selection
Corrective Actions As Required
Audits Conducted
Audit Results
Industry experts manage all key steps