nadcap supplier symposium - performance review institute...2013/09/06 · / 1 ac7109 / 4 ac7109 / 5...
TRANSCRIPT
Nadcap Supplier Symposium The National Motorcycle Museum in Solihull on 25th September 2013
The Bodycote Experience UK Perspective
Gareth Armstrong Quality Manager UK
Bodycote Heat Treatments Limited
Agenda
Why we have Nadcap? Quality Management System Requirements A Brief Introduction to Bodycote / Relevant History Our Current Nadcap Status Challenges we Faced / What we Have Learned / Our Current Approach Benefits of Nadcap Disadvantages of Nadcap Suggested Future Opportunities & Recommendations
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Why do we have Nadcap?
Because our Aerospace Customers Mandate it.
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Quality System
Before you consider Nadcap you need to ensure your Quality Management System holds up.
Two Alternatives are available to you: 1 AC7004 offered by PRI 2 AS9100 (Revision C) / BS EN ISO 9100: 2009 by a Certification
Body Recognised by the I.A.Q.G.
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• Cost Saving Opportunity • Is ideal if your business solely services direct to Aerospace Nadcap Primes. •Check AC7004 is an acceptable QMS with both your Prime & Customer ?
• Is Internationally Recognised. • Foundations built on ISO 9001:2008 usually the minimum customer requirements for none aerospace industries. • Multiple / Several / Campus / Complex Certification Structures are available for larger organisations.
Quality Management Systems are built on the principle of continuous business improvement practices to enhance your company to become successful.
Nadcap is about Technical Compliance to improve / maintain Aircraft Safety and Ensure the supply chain complies to all specified technical requirements.
Largely YES
They both have their place and separate benefits but some areas can over lap. e.g. Internal Auditing of Special Processes & Contract Review Effectiveness.
QMS and Nadcap is there a Difference?
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Today
Bodycote is the leading provider of thermal processing services worldwide, offering subcontract:
Global Presence 6
Heat Treatment Metal Joining Surface Technology Hot Isostatic Pressing
Over 190 Specialist Facilities In 26 Countries
History
Bodycote was founded in 1923, originally a British textile company.
Bodycote sole focus switches into Metals Processing & Testing Industries from 1979 onwards.
Bodycote has rapidly expanded to present day by successful technology acquisitions and organic growth built on good customer service and a reputation for quality.
1986 Bodycote UK achieve BS 5750 the foundations that developed into today's Quality Management System BS EN ISO 9001:2008 & BS EN 9100 : 2009 on a Multiple Certificate Structure spanning 21 locations. This also today incorporates Nadcap procedures.
2003 Bodycote UK enters the Nadcap Program & drops Civil Aviation Authority registration for HT & EBW.
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Nadcap Status
Today Bodycote (UK) has 15 Nadcap Approvals Spanning across 13 locations.
The other 8 facilities service other industries where Nadcap is not required but we do take some of the benefits learned into there daily operations.
We have experienced 116 Nadcap audits over the last 10 years.
Nadcap approvals cover 3 Special Process Commodity Groups & Specific Testing:
Heat Treatments
Fusion Welding
Coatings
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UK Commodity Matrix – Heat Treatments
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HEAT TREATMENTS AC7102
AC7102 / S
AC7102 / 1
AC7102 / 2
AC7102/3
AC7102 / 4
AC7102 / 5
AC7102 / 6
AC7102 / 7
AC7101 / 3
AC7101 / 4
Active Location 2013
HT Base Line
Prime Specific Brazing Aluminium Carburizing Nitriding
Hardness Testing HIP
Induction Hardening
Tensile Testing
Lab Metallographic & micro
Hardness
Cambridge YES YES YES NO NO NO YES NO NO NO NO
Chard YES YES NO NO YES YES YES NO NO NO YES
Chesterfield YES YES NO NO NO NO NO YES NO NO NO
Coventry YES YES YES NO NO NO YES NO NO NO NO
Derby YES YES NO NO NO NO NO YES NO NO NO
Hereford YES YES NO NO NO NO NO YES NO NO NO
Macclesfield YES YES NO NO YES NO YES NO NO NO YES
Rotherham YES YES NO NO NO NO YES NO NO NO NO
Skelmersdale YES YES YES NO NO NO YES NO NO NO NO
Stillington YES YES NO NO NO NO YES NO NO NO NO
Stockport YES YES YES NO NO YES YES NO NO NO YES
Woodford YES YES YES NO NO NO YES NO NO NO NO
UK Commodity Matrix – Welding & Coatings
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EBW AC7109
AC7110
/ 3 AC7110
/ 3 S AC7110 /
12 AC7110 /
12 / S AC7110 /
13 AC7110
/ 3
Active Location 2013
Fusion Welding
Base Line
Electron Beam
Welding
EBW Prime
Specific Welder
Qualification
Welder Qualification
Prime Specific
Evaluation of Welds
Evaluation of Welds Prime
Specific
Cambridge YES YES YES YES YES YES YES Skelmersdale YES YES YES YES YES NO NO
HVOF / Plasma AC7109 AC7109
/ 1 AC7109
/ 4 AC7109
/ 5
Active Location 2013 Coatings Base Line Thermal Spray
Coatings Chemical Stripping
of Coatings Coating Evaluation &
Lab Practices
Newport YES YES YES YES
Nadcap – NCR Analysis as end 2012 (Includes both Major + Minor)
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Site Type Total Audit NCR's NCR's per Day NCR's per Check Sheet
Cambridge W 3 1.5 0.4
Cambridge HT 1 0.3 0.3
Chard HT 4 1.0 0.7
Coventry HT 2 0.5 0.5
Derby HT 0 0.0 0.0
Macclesfield HT 2 0.7 0.4
Newport C 6 2.0 2.0
Rotherham HT 3 0.8 1.0
Skelmersdale HT 5 1.3 1.3
Skelmersdale W 1 0.5 0.2
Stillington HT 2 0.5 0.7
Stockport HT 3 0.8 0.5
Woodford HT 2 0.5 0.5
UK Average 2.6 0.8 0.6
Jan 2013 – All 10 HT & 2 W Sites Simultaneously on Merit
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Site Type Current Status Jan 2013 Audit Frequency
Cambridge W Maintain MERIT 18 Months Cambridge HT Maintain MERIT 24 Months
Chard HT Maintain MERIT 18 Months Chesterfield HT (HIP) Approved (New) 12 Months
Coventry HT Gain MERIT 18 Months Derby HT Maintain MERIT 24 Months
Hereford HT (HIP) Approved (New) 12 Months Macclesfield HT Maintain MERIT 24 Months
Newport CT Approved 12 Months Rotherham HT Maintain MERIT 18 Months
Skelmersdale HT Maintain MERIT 18 Months Skelmersdale W Maintain MERIT 24 Months
Stillington HT Gain MERIT 18 Months Stockport HT Maintain MERIT 18 Months Woodford HT Gain MERIT 18 Months
Culture Changes for Nadcap Implementation
Suppliers Must accept all Nadcap check sheet answers are either YES or NO.
Any Ambiguity = NO = NCR The site Metallurgist or site Weld Engineer / Coatings Engineer do not
have the authority to deviate or accept any deviation from Prime Specifications no matter how trivial.
A big culture hurdle to overcome when the process house and site expert “Metallurgist” is seen as the “Processing Technical Expert” by both internal & external customers.
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Challenges to Over come – Flow Down
The cascading of Prime Specific requirements down through the supply chain to the Special Process Provider.
The ideal situation is where all the requirements related to product and Prime Specific Quality Systems requirements flowed down like a cascade via the 1st Tiers.
Unfortunately in the real world it doesn’t often work like this and sometimes we have to educate our customers. – known as ‘Flow Up’
How? Implement a Robust Contract Review System.
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Lesson Learned ~ Robust Contract Review
Contract Review is not Commercial: Price Checks & T & C’s or Goods Inwards Inspection.
Contract Review looks at all the technical / compliance aspects needed to meet both customer & prime specification / drawing requirements – and whether we have the capability / capacity to meet them.
Be prepared to stand by your Contract Review System until questions are answered satisfactory and in
writing from the prime / design authority (not the first tier customer), irrespective of: – Urgent Customer Delivery Requirements – Aircraft on the Ground – All associated pressures applied through the supply chain
Parts must be Right First Time & Every Time.
Apply a Zero Risk Culture to your Business.
Try to Treat all products the same: do not differentiate between Aerospace and Non-Aerospace
products at your facility, until all technical requirements are fully understood.
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? Confused
& Frustrated
Auditor Inconsistency
Opinion Interpretation
1st Tier, 2nd Tier, 3rd Tier
etc Interpretation
Special Process Provider
Interpretation
Prime & Customer
Requirements
Clarify in Writing with the Prime or Design Authority
Before Processing.
You Need to build good Prime contacts to assist / interpret technical requirements.
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Why have we received a audit NCR if it was acceptable at the last audit?
Lessons Learned Invest / Upgrade in the latest technology examples include: furnace autonomous control –
remove / reduce the human manual factors / de-skill through process control systems.
You need to build Strong Supplier Relationships examples: – Thermocouple Manufacturers – Equipment Manufacturers – Calibration Services – Laboratories & Test Houses
Train & Develop your People all Levels:
– Metallurgy – Pyrometry – Contract Review / Data Card Construction – Inspection / Testing / Evaluation – Root Cause & Corrective Action
Strengthen by Standardisation / Common Approach across locations – by sharing information.
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Benefits of Nadcap
Business Security & Retention.
Enhanced Reputation for Quality & Technical Excellence.
Confidence that Process Controls are of the Highest Standard. Prestige. After 10 years we are finally starting to see, less Prime Audits and more
acceptance of just the Nadcap audit.
Higher conformance to Prime requirements.
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Disadvantages of Nadcap
Cost of Audits Additional day to day people costs to maintain the necessary quality /
conformance level.
Potential delay in supply chain Turn Around Times to clarify requirements.
Major Drain on site Quality / Technical Resource of Time Spent.
– Preparing for audits (Perform as many Self Assessments as possible) – Participating (Team Approach) – Answering NCR’s
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Future Opportunities & Suggestions
Mutual Supplier Benefits ~ All Subscribing Special Process Providers need to have more say & involvement into the future program – How ?.
Nadcap audits should not be scheduled by PRI at supplier meetings.
PRI should continue to offer ‘Free Training Sessions’ at Supplier
Meetings.
Heat Treatment Primes need to work towards one Global Pyrometry / Processing Standard.
Like to see Introduced a Flow Down Check Sheet for Tier Manufacturers
who purchase Special Processes to verify: – Accurate Flow down to sub special process suppliers – Adequate verification of purchased services
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