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Welcome to NadcapNational Aerospace and Defense ContractorsAccreditation ProgramNadcap impact on NDT
Agenda What is Nadcap?Why Nadcap?The Nadcap members (Primes)The key steps– Audit criteria– Audit content NDT audit– Audit process Nadcap impact on NDT– Level 3 responsibilities– NDT related procedures– Responding to NCR’s Lessons learned The Fokker approach2Nadcap NDT November 8, 2012UNCLASSIFIED
What is Nadcap? Nadcap National Aerospace and DefenseContractors Accreditation Program The leading, worldwide cooperative program of majorcompanies designed to manage a cost effectiveconsensus approach to special processes andproducts and provide continuous improvement withinthe aerospace industry.3Nadcap NDT November 8, 2012UNCLASSIFIED
Why Nadcap? Nadcap accreditation has become a basic requirementin the Aerospace business All major Aerospace manufacturers (customers),require Nadcap accreditations (customer requirement) Nadcap accredited companies that subcontract“special processes”, shall flow down customerrequirements including Nadcap Fokker is accredited for:––––4Non Destructive TestingHeat TreatingChemical ProcessingCompositesNadcap NDT November 8, 2012UNCLASSIFIED
Nadcap members (Primes)MTU Aero Engines5Nadcap NDT November 8, 2012Vought AircraftUNCLASSIFIED
The key steps .ProcessEvaluation andImprovementAuditorQualification& selectionCorrectiveActions AsrequiredAuditsConductedAudit results6Nadcap NDT November 8, 2012UNCLASSIFIED
Relationship between Audit Criteria (AC),Auditor Handbook and Prime RequirementsAC7XXXAUDITCRITERIA Job AuditsIndustry Standards PrimeRequirements7Nadcap NDT November 8, t.comUNCLASSIFIED
Audit Content NDT audit (basic) The Nadcap NDT Task Group is responsible for theoperation of the Nondestructive Testing accreditationprogram and are currently utilizing the followingNadcap NDT baseline checklists:–––––––8AC7114 – Nondestructive TestingAC 7114/1 – Liquid PenetrantAC 7114/2 – Magnetic ParticleAC 7114/3 – UltrasonicAC 7114/4 – RadiographyAC 7114/5 – Eddy CurrentAC 7114/6 – DDA Radiography (Draft)Nadcap NDT November 8, 2012UNCLASSIFIED
Audit Content NDT audit (supplemental) Previous mentioned checklists contain“Compliance Assessment Guidance” whereclarification is necessary to confirm the TaskGroup requirements In addition to the baseline checklists, thesupplier is also audited to Prime User Memberrequirements , defined in Baseline Supplements:–––––9AC7114S – Supplemental Audit Criteria NDT TestingAC7114/1S – Supplemental Audit Criteria Liquid PenetrantAC7114/2S – Supplemental Audit Criteria Magnetic ParticleAC7114/3S – Supplemental Audit Criteria UltrasonicAC7114/4S – Supplemental Audit Criteria RadiographyNadcap NDT November 8, 2012UNCLASSIFIED
Nadcap – The audit processTaskGroups(Primes)Nadcap StaffSuppliersPerformAuditFindingReview &Accept C/ASubmit C/ApackageAccreditSupplierReview C/ApackageeAuditNet10Nadcap NDT November 8, 2012EstablishAuditCriteriaUNCLASSIFIED
Nadcap Impact on NDTLevel 3 responsibilities Level 3; “the Spider in the Nadcap web” Level 3 needs accountability for identifying andassuring customer NDT requirements for:––––––––Review of NDT requirementsSequence of NDT operationsNDT procedure development and approvalNDT technique development/review and approvalTraining of NDT personnelExamination of NDT personnelApproval of NDT internal audit personnelAnnual review of processing and inspection of hardware foreach certified individual qualified to process hardware– Determining/documenting of training adequacy/equivalency– Review of calibration certificates11Name of the presentationUNCLASSIFIED
Nadcap impact on NDTNDT related procedures Each method requires a procedure (general orspecific) for processing and inspection NDT procedures need to indicate––––approval by the applicable Level 3Traceability to name and address of the facilityIdentification number and date of approvalA requirement that all personnel are qualified and certified tothe required level for the activity undertaken– Part number and/or material to be examined– All processing parameters– Identification of the component or areas within a componentto be inspected12Name of the presentationUNCLASSIFIED
Nadcap impact on NDTNDT related procedures– Traceability to customer acceptance criteria– Requirements for special equipment if different fromstandard processing– Complete pre- and/or post-treatment instructions, includingall details in accordance with customer requirements orreference to procedures containing such instructions– Description for the method of identifying inspection status– Method for control of software or programming used forautomated processing equipment as applicable– All required process control tests and checks Don’t assume – review the information and verify forcompliance. Even if you know the system, test theprocedure.13Name of the presentationUNCLASSIFIED
Nadcap impact on NDTNDT related procedures Nadcap requires a procedure that flows downcalibration requirements for NDT related equipment :– Accuracy/Range (number of points to be checked for eachinstrument and reference to the accuracy per range– Criteria to extend or reduce the calibration frequency14Nadcap NDT November 8, 2012UNCLASSIFIED
Nadcap impact on NDTNDT related procedures Nadcap requires a procedure that covers an annualinternal audit of NDT system, including:– Review of NDT inspection process– Review of associated documents such as travelers, planningdocuments and inspection reports– Review of personnel certifications for existence andcompleteness– Review of NDT process procedure for adequacy andequipment15Nadcap NDT November 8, 2012UNCLASSIFIED
Impact on NDTNadcap NCR’s Root Cause Analysis Nadcap style– Immediate corrective action– What have you done to stop the bleeding– Root Cause of non-conformance– Which failure(s) in process / working methods / etc. resulted innonconformance– Impact of all identified causes and the root cause– Always review possible impact on parts. Take appropriateactions to correct actual and/or earlier produced parts– Action to prevent re-occurence– What actions have been taken to prevent the nonconformanceto happen again– Objective evidence– Mention (and attach) copies of all evidence available to provethe corrective & preventive actions have been implemented– Effectivity date16Name of the presentationUNCLASSIFIED
Lessons learnedCommon mistakes initial NDT audit –––––––––17Underestimating the impact of NadcapLack of audit preparationUnfamiliarity with Nadcap can result in many NCR’sClosing NCR’s (Root Cause Analyses) requires some skillsNadcap baseline requirements not metFocusing on own organization instead of customerLots of recording and witnessing issues NDT dataIncomplete training recordsThe “we already work this way for 25 years” approach .Nadcap NDT November 8, 2012UNCLASSIFIED
Lessons learnedHow to prepare for your audit –––––––––18Take your time (initial audit six months)Make it teamwork (all disciplines involved)Answer each checklist questionAssign the checklist questions to responsible departments(teams)Refer to internal procedure number(s) and applicableparagraph(s)“No” is the wrong answer! Make sure you take appropriateactions to convert “No” into “Yes”Use the auditors handbook, it is loaded with additionalinformation for the checklist questionsCollect objective evidence for each checklist questionOrganize frequent meetings to check progressNadcap NDT November 8, 2012UNCLASSIFIED
Lessons learnedHow to prepare for your audit – Perform job audits to check compliancy to Nadcaprequirements– Create an action list to keep track of changes– Make sure your customer requirements are covered in yourinternal procedures– Where the Nadcap baseline requirement is tighter than yourcustomer requirement, the Nadcap baseline requirementshall be fulfilled19Nadcap NDT November 8, 2012UNCLASSIFIED
The Fokker approach(continuous improvement)–––––––20Implementation 5SPull system (customer driven production)JIT objectivesFirst time right (Six Sigma)Responsibility transfer to shop floor (empowered teams)Visual management ( what and how, visible in one view)Continuous improvement (elimination of waste never stops)Nadcap NDT November 8, 2012UNCLASSIFIED
The Fokker approach21Nadcap NDT November 8, 2012UNCLASSIFIED
Finally .Some helpful Tools Nadcap Root Cause Analyses training Visit a Nadcap meeting Check all information on www.eauditnet.comAny questions?22Name of the presentationUNCLASSIFIED
– Responsibility transfer to shop floor (empowered teams) – Visual management ( what and how, visible in one view) – Continuous improvement (e
