NADCAP NEWSLETTER JULY 2016 CONTENTS 1 RCCA Nadcap Style 5 Nadcap Welding Audit Insights 11 Review of Nadcap Mark of Conformity Usage 12 How to use the Qualified Manufacturers List 15 Nadcap Supplier Survey Results WELCOME TO THE FOURTH ISSUE RCCA NADCAP STYLE In the March 2016 issue of the Nadcap Newsleer, part one of Geng To The Root was published. That arcle provided an overview of the inial stages of root cause analysis and correcve acon implementaon including containment, forming a team, gathering and analyzing data and determining causes and impacts. Part two focuses on idenfying a soluon and assessing it to ensure effecveness. Connued on next page This is the fourth issue of this Nadcap newsleer. PRI has been publishing and sharing this content for one year now. I would like to thank everyone who has given us feedback to help improve this newsleer, and for the posive comments my staff and I have received on the content to date. The intent of the newsleer connues to be to develop content for companies that are not normally able to send a representave to Nadcap meengs, to share technical informaon/knowledge that will help them beer prepare for a Nadcap audit and understand how to ulize Nadcap effecvely to improve their performance. Each newsleer includes arcles designed for the whole Nadcap Supplier community. In this issue, there is an arcle clarifying the appropriate use of the Nadcap mark of conformity, and one with ps about how to best use the online Qualified Manufacturers’ List (QML) on eAuditNet. Also highlighted are the results of the biennial Nadcap Supplier Survey that the Nadcap Supplier Support Commiee released late last year, as well as the connuance of the arcle on root cause correcve acon from the previous newsleer edion. In addion to general Nadcap arcles, each newsleer will have a parcular technical focus. In this issue, there is detailed informaon regarding Nadcap welding audits. Nearly 500 Nadcap welding audits are conducted annually, yet we know that many people are not able to aend Nadcap meengs and benefit from free training and other informaon shared there. I hope you connue to find the content valuable. Joseph G. Pinto Execuve Vice President & Chief Operang Officer Performance Review Instute IN BRIEF... Nadcap is an approach to conformity assessment that brings together technical experts from Industry to manage the program by establishing requirements for accreditaon, accreding Suppliers and defining operaonal program requirements. This results in a standardized approach to quality assurance and a reducon in redundant auding throughout the aerospace industry. Nadcap is administered by the Performance Review Instute (PRI), a not- for-profit organizaon headquartered in the USA with satellite offices in Europe and Asia. www.p-r-i.org/Nadcap/ Overview of Root Cause Cause Correcve Acon (RCCA) - Nadcap Style (Part Two)
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NADCAP NEWSLETTER
JULY 2016
C O N T E N T S
1 RCCA Nadcap Style
5 Nadcap Welding Audit Insights
11 Review of Nadcap Mark of Conformity Usage
12 How to use the QualifiedManufacturers List
15 Nadcap Supplier Survey Results
WELCOME TO THE FOURTH ISSUE
RCCA NADCAP STYLE
IntheMarch2016issueoftheNadcapNewsletter,partoneofGetting To The Rootwaspublished.Thatarticleprovidedanoverviewoftheinitialstagesofrootcauseanalysisandcorrectiveactionimplementationincludingcontainment,formingateam,gatheringandanalyzingdata and determining causes and impacts. Part two focuses onidentifyingasolutionandassessingittoensureeffectiveness.
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ThisisthefourthissueofthisNadcapnewsletter.PRIhasbeenpublishingandsharing this content for one year now. I would like to thank everyone who hasgivenusfeedbacktohelpimprovethisnewsletter,andforthepositivecommentsmystaffandIhavereceivedonthecontenttodate.
EachnewsletterincludesarticlesdesignedforthewholeNadcapSuppliercommunity.Inthisissue,thereisanarticleclarifyingtheappropriateuseoftheNadcapmarkofconformity,andonewithtipsabouthowtobestusetheonlineQualifiedManufacturers’List(QML)oneAuditNet.Alsohighlightedarethe results of the biennial Nadcap Supplier Survey that the Nadcap Supplier SupportCommitteereleasedlatelastyear,aswellasthecontinuanceofthearticleonrootcausecorrectiveactionfromthepreviousnewsletteredition.
Joseph G. PintoExecutiveVicePresident&ChiefOperatingOfficerPerformanceReviewInstitute
I N B R I E F. . .
Nadcap is an approach to conformity assessment that brings together technical experts from Industry to manage the program by establishing requirements foraccreditation,accreditingSuppliersanddefiningoperationalprogramrequirements. This results inastandardizedapproachto quality assurance and areductioninredundantauditingthroughouttheaerospace industry.
Nadcap is administered by the Performance Review Institute(PRI),anot-for-profitorganizationheadquartered in the USA withsatelliteofficesinEurope and Asia.
Preventivecorrectiveactioncanalsobethoughtofassustaining,becauseyoucannotpreventtheeventatthispoint.Ithasalreadyoccurred.Actionstakennoware intended to prevent the problem from recurring. The goal is to break the cause chain by addressing thecontributingcausesaswellastherootcause.Itisimportanttoresolvethecontributingcauses,notjusttherootcause,becausefailuretodosocouldleadtoacontributingcausebecomingafuturerootcause.
Althoughpreventiveactionmaybeoneaction,itcouldalsobeaseriesofactions,thatpositivelychangeormodifysystemperformance.Nadcapis,afterall,aprocessauditsothisisaboutmakingconstructivechanges to the systems that support the process in order topreventeventrecurrence.Preventiveactionfocuseson systemic changes and the points in the process where thereispotentialforfailure.Thisincludescontributingcauses as well as direct and root causes.
Thefocusofpreventiveactionisnotindividualperformance,humanerrororpersonnelshortcomings.Consequently,“Operatorerror”isnotanacceptablerootcauseresponsetoanon-conformanceidentifiedin a Nadcap audit. It is the company and its processes beingaudited,nottheindividual.
Sothequestiontoaskyourself,ifyougetstuckatthepointofhumanerrorasarootcause,is:ifthatindividualwasnotworkinghereanymore,wouldthatmakeitimpossible for this issue to occur again?
The answer is almost certainly no. If one individual can makeamistake,itmeansthereiselasticityinthesystemtoallowthemtodoso,anditistheresponsibilityofthecompanytoclosethosegaps,whethertheyareprocedural,trainingorotherwise.Whendevelopingthesolution,itisworthbearingsomeguidelinesinmind:
1. Acceptthatthereisnoperfectsolution.Anysolutionthatyouandyourteamthinkofwillbesubjecttoanumberoffactors(seea-fbelow).Insomecases,therefore,youmayberequiredtomakeajudgmentcallastotheappropriatesolution,basedonyourknowledge of the company and the issue.
Theremustbeareasonableexpectationthatthesolutionwillfixtheproblemthathasbeenidentified.Asolutionthatisnoteffectiveisnotonlyawasteoftimeandresources,butitcreatesariskthattheproblemwillrecurwhich,apartfromanythingelse,couldresultinamajornonconformance at the next Nadcap audit due to non-sustainingcorrectiveaction.
Aspreviouslydescribed,thefocusofthecorrectiveactionshouldbeonthesystemicissueintheprocess,notonthe personnel involved. While operators domakemistakes,thekeyistoidentifytheconditionsthatmadethatmistakepossible.Forexample,weretheinstructionsclearandeasilyaccessible?Had there been recent personnel changes? etc.
f) Contingency Planning
Whileitisexpectedthatthesolutionwillsucceedataddressingtheissue,itmaybeflawed.Criticalpartsofthesolutionitselfshouldbesubjecttocontingencyplanningto ensure that a misstep at any point doesnotcauseabreakdownoftheentiresolution.
2. Taketimetoreachasolutionandensure you give adequate
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considerationtoalternatives.Itiskeytohaveanopenmindandtofollowthechainwhereitleads,even if that is to your department or a procedure youhavewritten.Alwaysrememberthatthekeyistofixtheproblem.
3. Be open to the possibility that what you have identifiedastherootcausemayactuallybeasymptom of a larger problem. Keep following the chain as far as is reasonable and create as many chainsasneededtoexhaustthepossibilitieswithinthecompany’scontrol.
4. Challengeassumptions.Youmayknowyouroperationwell,butbepreparedtorevisitassumptionsthatarenotsupportedbyevidence.Make sure you have the evidence available because althoughyoumaynotneedit,theNadcapauditor,auditor reviewer and Task Group might.
Aspartoftheassessmentofthecorrectiveaction(s),itisimportantthatamemberoftheteamconductsafollow-up review to ensure that they were fully and properly implementedasstatedinyournon-conformanceresponseineAuditNet,asthisiswhatthenextauditorwill be looking to verify.
Thecorrectiveactionsmustbeinstitutedasstatedand it is key that someone is given the responsibility of ensuring that is the case. Part of their task is to read thecorrectiveactionresponseliterallyandcheckthat
Whendevelopingthecorrectiveactions,bearinmindthelevelofscrutinythattheywillbesubjectedto,andensure that the team can deliver according to what is written.Becarefulintheterminologyyouuse-wordslike“everyone”,“always”etc.maycauseyouproblemslater. Remember that you will have to show that you havedonewhatyousaidyouwouldthroughobjectiveevidence. The easiest way to be able to do that is to have that at the front of your mind during the process of developingandwritingthecorrectiveactions.
Another part of the assessment process is to validate theeffectivenessofthecorrectiveactions.Didtheyachieve the intended outcome? The only way you will knowisbydefiningthecriteriaforeffectivenessandacceptabilityinadvance.Withoutthesebenchmarks,itwillbedifficulttomeasuretheoutcome.
Again,bearinmindthattheeffectivenessofthecorrectiveactionswillbeverifiedbytheNadcapauditorduringsubsequentaudits.Non-sustainingcorrectiveactionsareoneofthebiggestsourcesoffindingsacrossall Task Groups and can be cause for removal of Supplier Meritsoitiswellworthputtinginthetimeupfront.
Part one of RCCA Nadcap Style was published in issue three of the Nadcap Newsletter, dated March 2016, and is available on the PRI website www.p-r-i.org under Key Documents.
RCCA NADCAP STYLEContinued from previous page
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NADCAP WELDING AUDIT INSIGHTS
The Nadcap Welding Task Group was established in 1994 and is currently led by Chairperson Steve Tooley fromRolls-Royce,supportedbyViceChairpersonHolgerKruegerfromAirbus.WithintheTaskGroup,thereareover50industryrepresentatives.Theyparticipateintechnicaldiscussionsanddecision-makingthreetimesperyearatNadcapmeetings.
For those industry stakeholders who are unable to attendtheNadcapmeetingsorthetechnicalsymposiaandbenefitfromtheopportunitytoparticipateandlearnaboutNadcapweldingauditsface-to-face,theintentofthisarticleistoprovidesomeinsightintocommonnonconformances(NCRs)foundduringNadcapweldingaudits,froma“lessonslearned”perspective.
Processspecificrequirementshavebeendevelopedby the Welding Task Group and are contained in the AC7110seriesofchecklists:
• AC110:Welding/TorchandInductionBrazing
• AC110/1:Brazing(TorchandInduction)
• AC110/2:Flashwelding
• AC110/3:ElectronBeamWelding
• AC110/4:ResistanceWelding(Spot,Seam,Projection)
• AC110/5:FusionWelding
• AC110/6:LaserWelding
• AC110/7:RotationalFriction/InertiaWelding
• AC110/8:DiffusionWelding
• AC110/9:PercussionStudWelding
• AC110/12:Welder/WeldingOperatorQualification
• AC110/13:EvaluationofWelds
These checklists are available on eAuditNet under Resources-Documents-AuditChecklistsand,aswithanyNadcapaudit,youshoulddownloadandreviewthem in detail in advance of the actual Nadcap audit as partofyourpre-auditpreparation.
Additionalinformationonthechecklistrequirements,questionintent,acceptableobjectiveevidence,examples of NCRs and helpful hints are included in the audit handbooks that are also available in eAuditNet in the Public Documents area.
Top Nonconformances in Welding Audits
IncommonwithmanyotherNadcapTaskGroups,theWeldingTaskGroupanalyzesandpublishescommonnonconformancesidentifiedduringNadcapauditsonaregular basis. The intent is to help suppliers avoid some commonpitfallsandstrengthentheirinternalprocesscontrol.
The Welding Task Group most recently published an updated document in February 2016. The most recent guidance released by the Nadcap Welding Task Group is below.
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The document is also posted in eAuditNet under Resources-Documents-PublicDocuments-Welding-SupplierInformation.SimilardocumentsforotherTaskGroups are posted in Public Documents. It is strongly recommendedthatyoureviewtherelevantfilestogaininsightsthatwillassistinNadcapauditpreparationandsuccess.
Nadcap Welding Audit Insights
ThefollowingchecklistquestionsarethemostcommonthatNCRsarewrittenagainst.Additionalinformationonthechecklistrequirementincludingacceptableobjectiveevidence is included in the audit handbooks that are available in eAuditNet under Public Documents.
• This is a new checklist requirement that many Suppliers have not incorporated into their system. Suppliers must review new checklist revisions and implement changes into their system.
• Understandtherequirement.Don’tassumeyoualready have the item under control. Many Suppliers incorrectlyassumethatthisappliestoconsumables,wheninfactitappliestonon-consumableelectrodes as well.
• ReviewPurchaseorders,receiptdocumentationand electrode traceability to ensure it meets your procedureandanyspecificationsthatareflowedbycontract.
2)Arepre-weldpreparationsperformedasdescribedin documented procedures and in accordance with customer requirements?
Thisisacompliancequestionandisinparagraphs11,12and 13 of the weld process checklists.
• Inacontrolleddocument,specifyrequirementsformaterialpreparationasapplicabletowelding,includingcleaning,handbenching,handgrinding,handling between cleaning and welding etc.
• Ensure cleaning is addressed procedurally and includescustomer-specificrequirements,ifapplicable.
Thisisacompliancequestionandisinparagraphs11,12and 13 of the weld process checklists.
Explanation:Thesuppliermustdemonstratethattheparameters/settingandweldtasksspecifiedintheprocedure are being done in accordance with the approveddocument.Thisquestionisonlyaddressingcompliancetotheweldscheduleinuse,notcompliancetothecertification,approvalordocumentation
requirements.
Examplesoffindings:
• Supplierhasanapproved/certifiedweldscheduleanditisinuseattheworkstation,butthewelderisusing parameters outside the allowable range.
Thisisacompliancequestionandisinparagraphs11,12and 13 of the weld process checklists.
Explanation:Weldingequipmentrequiresperiodiccalibrationtoensurerepeatabilityofparameters.All equipment must be considered and addressed procedurally.Itisrecognizedthatsomeequipmentmaynotrequirecalibration,howeverthisequipmentshouldbeidentifiedthatthisisthecase(e.g.avoltmeterusedin
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NADCAP WELDING AUDIT INSIGHTSContinued from previous page
5)Isthereadocumentedproceduretoensurecleaningtools,suchasbrushes,flapwheels,abradingtoolsetc.are marked with the materialtype they are used on in order to avoid cross contamination?
Explanation:Inordertopreventcrosscontamination,cleaning tools are restricted to the material types they werefirstusedon.
Exampleoffindings:
• Nodocumentedproceduretodefinehowthe
Supplier will control cleaning tools to prevent cross contamination.
• System is not robust enough to prevent cleaning tools being used on more than one material type.
• Unidentifiedcleaningtoolsfoundinuseandhenceunable to prove which material types they can be used on.
• Cleaning tools made from materials that are prohibitedbyflowedspecification.E.g.carbonsteelbrushes used on nickel.
HelpfulHints:
• This is a new checklist requirement that many Suppliers have not incorporated into their system. Suppliers must review new checklist revisions and implement changes into their system.
• Spot check weld areas. Ensure cleaning tools are marked with the materials they can be used on.
• There is guidance on material types in the handbook.
• Aspartofauditpreparation,performaspotcheck of eyesight records. Look for compliance to specificationrequirements,thattherecordsarecurrent,thatrestrictionsaredocumented.
Thisisacompliancequestionandisinparagraphs11,12and 13 of the weld process checklists.
Explanation:Aweldschedulemustcontainallparameters/settingsrequiredbythecustomer(s).Theextentofparameterdocumentationrequiredmayvaryby customer. Having the appropriate approvals is also required.
Explanation:ToensuregasrequirementsarecorrectlydefinedtherebyensuringCustomerspecificationsare met. Hence to ensure shield gas does not contaminatetheweld/braze.Alsofortorchbrazingtoensurethatthefuelgasand
IfyouhaveanyquestionsonthisarticleoraNadcapweldingaudit,pleasedonothesitatetocontactany member of the Nadcap Welding department at [email protected] and we will be happy to help.
Mike GutridgeLeadSeniorStaffEngineerT:+17405879841E:[email protected]
Ian SimpsonAssociate Program ManagerT:+44(0)1332869272E:[email protected]
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REVIEWOFNADCAPMARKOFCONFORMITYUSAGE
ObtainingNadcapaccreditationisaremarkableachievement.Manycompanies,understandably,wishtopromotetheirstatustotheircustomersspecifically,andto the industry as a whole. One of the ways to do this is toutilizetheNadcapMarkofConformityinyourefforts.
The Nadcap Mark of Conformity is a version of the Nadcaplogothataccreditedcompaniesareauthorizedtoutilizeinveryspecificways,anditisimportantthatthisisdone correctly.
Nadcap logo Nadcap Mark of Conformity
ThedifferencebetweenthelogoandtheMarkofConformityisthatthelatterincludesthewordAccredited. Proper use of the Mark of Conformity is describedins-frm-48,whichislocatedoneAuditNet(www.eAuditNet.com)underResources-Documents-ProceduresandForms-NadcapControlledForms-sforms. A summary of the appropriate way to use the Mark of Conformity is described below but please refer tos-frm-48oneAuditNetforfulldetails.
One of the most important points about using the Mark of Conformity correctly is that you must ensure that the commodity/commoditiesforwhichyourcompanyisaccredited are detailed as well. The Mark of Conformity should not appear alone. This enables anyone who sees the Mark of Conformity to understand your accredited status at a glance and avoids confusion.
NondestructiveTesting Welding
Incorrect Correct
Asexplainedins-frm-48,itisthecompany’sresponsibilitytoensurethat“noconfusionarisesaboutthescopeofaccreditation”.Omittingthecommodity/commoditiesforwhichthecompanyholdsaccreditationis the most common mistake made by companies using the Mark of Conformity.
WhenaNadcapaccreditationisissued,camera-readyartworkand/orelectronicfilesarealsosent.Otherelectronic formats are available upon request.
IntermsofapplicationoftheMarkofConformity,itmaybeusedinmanyways.s-frm-48referstocompanyletterhead,faxcoversheets,businesscardsand“otherbusinessstationery”,aswellaswebsite,flyers,mailings,paidadvertisementsinmagazinesandtradepublications,companypromotionalmaterialsandcompanysouvenirs.Thisisaverybroadlistandoffersalotofopportunitytopromote your Nadcap status.
As long as the Mark of Conformity is being applied in compliancewiths-frm-48,theseareallacceptableuses.
Another key point to be aware of is that the Mark of Conformityisnottransferrablebetweenfacilitiesorlocations.Thismeansthatcompanieswithmultiplefacilitiesorlocationsmustindicatewhichfacilityorlocationisaccredited.
UtilizingtheMarkofConformitycanbeinvaluableinensuring that the hard work of you and your colleagues is noted by your customers and the industry at large.
IfyouhaveanyquestionsaboutobtainingorusingtheMarkofConformity,pleasedonothesitatetocontactyourCommodityServiceRepresentative(CSR).ThelistofcontactsisavailableoneAuditNet under Contact Us.
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HOW TO USE THE QUALIFIED MANUFACTURERS LISTAllcompaniesinpossessionofavalid,currentNadcapaccreditationarefeaturedontheonlineQualifiedManufacturersList(QML)oneAuditNetatwww.eAuditNet.com.
TheQMLservesanumberoffunctions.ForcompanieswithNadcapaccreditation,itprovidesareliable,independent source that they can direct their customers toinordertoverifytheirNadcapstatus,orscopeofaccreditation.Forthoselookingtosourcesupplierswithconfidence,theQMLactsasasearchabledatabase,updatedinrealtimeasaccreditationsaregrantedandexpire.ThisenablesuserstofindNadcapaccreditedcompaniesinaconvenientlocation,withtheprovencapability to do the work required.
OnceyouhaveloggedintoeAuditNet,theQMLcanbeaccessed via the Resources menu.
Thistakesyoutothedatabasesearchenginewhich,basedonthecriteriayouselect,willreturnalistof Nadcap accredited companies that meet those requirements.Thecriteriaavailableare:
Clicking on the Excel icon(6)willdownloadtheresultstoyourcomputerwheretheycanbesavedorprinted.Inthiscase,withonlytworesults,thatmaynotbenecessary,butdependingonthesearchcriteria,theremaybehundredsorpotentiallythousandsofresultsandtheabilitytoviewtheminaformatthatallowsyoutoworkwiththedatacanbe invaluable.
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NADCAPSUPPLIERSURVEYRESULTSOnabiennialbasis,theNadcapSupplierSupportCommittee(SSC)conductsasurveyoftheglobalsupplierbase. This survey has been issued every two years since 2003,andwasmostrecentlylaunchedin2015.
DaleHarmonofCincinnatiThermalSpray,SSCChairperson,explainswhythisissuchanimportantactivity:“Forovertenyearsnow,theSSChasworkeddiligently to ensure that the Supplier voice is heard withintheNadcapprogram,inanumberofways.TheSurveyisoneofthemostvaluable,becauseitenablesustounderstandtheexperiencesofabroadcross-sectionoftheNadcapSuppliercommunity,givingusinsightsthatwewouldnototherwisehaveaccessto.”
LeiBaoofNCSTestingTechnologyCo.,Ltd.istheSSCAsianrepresentativeandledthe2015SupplierSurveyteam.Heisdelightedwiththeresponserate:“ItwasmyprivilegetoleadsuchanenthusiasticteamandIamveryhappy that this survey received the highest ever number ofresponses.Thankyoutoeveryonewhotookthetimetosharetheirfeedback.”
Finally,JoePinto,ExecutiveVicePresidentandChiefOperatingOfficerforthePerformanceReviewInstitute,whichadministersNadcapadded:“Ihavelongbeenan advocate of the idea that Nadcap is a program as much for the Suppliers as it is for the Subscribers. Every timeSuppliersutilizetheopportunitiesopentothemtoparticipateinNadcap,wealltakeastepclosertothisvision.Iwouldliketoaddmythankstothe3,200individualswhotookpartinthesurvey.Yourcontributiondoesmakeadifference.”