Surface Enhancement

NONCONVENTIONAL MACHINING &

SURFACE ENHANCEMENT

JUNE 2011

UNCONFIRMED MINUTES

JUNE 20-24, 2011

GRAND CONNAUGHT ROOMS

LONDON, ENGLAND

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, JUNE 20 – THURSDAY, JUNE 23, 2011

1.0 OPENING COMMENTS / MEETING RULES AND GUIDELINES– OPEN

The Nonconventional Machining & Surface Enhancement Task Group (NMSETG) was called to order at 9:00 a.m., 20-Jun-11.

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:

User Members/Participants Present (* Indicates Voting Member)

NAME / COMPANY
* / Angelie / Vincent / Spirit AeroSystems / Chairperson
* / Alex / Pohoata / Honeywell / Vice-Chairperson
* / David / McCallister / UTC-Pratt & Whitney / Secretary
* / Silvia / Baeza / Triumph-Vought
* / Aaron / Havlovic / Cessna Aircraft Company
N. Hakan / Karaaslan / GE Aviation
Parmjit / Khera / GE Aviation
* / Gudrun / Muehlbauer / MTU Aero Engines
* / K.T. / Quader / The Boeing Company
* / Paul / Woolley / Rolls Royce plc
Evren / Yuksekkaya / GE Aviation
Brad / Richwine / Raytheon
Serge / Labbe / Heroux Devtek

Other Members/Participants Present (* Indicates Voting Member)

NAME / COMPANY NAME
Ed / Mayer / Meyer Tool Company
Rob / Dicks / Metal Improvement Company
Rick / Scott / Rich Technology International
Gigi / Streeter / Barnes Aerospace Lansing
* / Yoshiomi / Sukesada / Asahi Kinzoku Kogyo Inc.
Andrea / Wangsanegara / Pudac Scientific
Toshiyuki / Serizawa / IHI Corp

PRI Staff Present

Richard / Sovich

The NMSE Chairperson, Angelie Vincent of Spirit AeroSystems, opened the meeting by reviewing the Nadcap Personal Code of Ethics, Conflict of Interest, Antitrust Guidelines and NMSE Vision Statement. In review of the Vision Statement, several sections were identified as areas for potential update.

ACTION ITEM: Angelie Vincent will review and update the NMSE Vision Statement and report-out at the October Task Group Meeting. (DUE DATE: 17-Oct-2011)

1.1  Call for New Members

Evren Yuksekkaya (GE Aviation) expressed interest in becoming a new member. The Task Group verified previous attendance and unanimously approved him as a new member.

2.0 APPROVAL OF FEBRUARY 2011 MEETING MINUTES – CLOSED

Motion made to approve the minutes from the February 2011 Nadcap meeting. Motion Passed

The minutes from February 2011 were approved as written. They were no further comments

3.0 NMSE METRICS – CLOSED

Metrics were updated as May 2011

Topics:

·  2011 Task Group performance vs. goals - 2011 performance is consistently exceeding goals.

·  Audits open more than 90 days - NMSE Task Group has an exceptional record and is rarely over 60 days.

·  NMSE Program cumulative year to date audits - audits are slightly over projected totals.

·  NMSE certificates issued - 50 audits were processed and approved in May 2011.

·  Total supplier cycle time - this metric has stabilized at 20 cumulative days.

·  Total staff cycle time - this metric has stabilized 7 cumulative days.

·  Total task group cycle time - this metric has stabilized at 8 cumulative days.

·  Percent of eligible processors - this metric has stabilized at 95%

·  Primes balloting corrective action packages – 80% of eligible balloting Primes are participating in balloting the corrective action packages.

·  Sector auditors required vs. capacity – capacity meets goals for the Task Group however with recent reductions in capacity and growth in other commodities that share auditors, more capacity for both NM and SE in the North American sector was identified as needed for future growth.

·  Auditor Cross-Training activity – 4 of 6 auditors identified for potential cross-training have completed training and approved by the Task Group as auditor trainees.

·  Staff Delegation was reviewed: period 01-Feb to 31-May, 2011

·  Rick Sovich – 106 Audits, 100% Concurrence, 89% Oversight

·  Joe Barr – 35 Audits, 92% Concurrence, 64% Oversight

·  Sarah Jordan – 1Audit, 100% Concurrence, 100% Oversight

·  Marcel Cuperman – review no audits during the review period

4.0 NMSE RAIL – CLOSED

·  Low air pressure alarm (or automatic shutdown) was discussed at length. Feedback from the AMEC-SE Standards Committee indicated that the topic will be addressed and a statement added to the applicable Industry specifications. Primes investigated internal requirements for low-level alarms located near the machine. The Task Group has tabled any changes to the current checklist requirement until after the topic is resolved by the Standards Committee.

·  Adequate lighting for surface coverage. Feedback from the AMEC-SE Standards Committee indicated that a general sentence will be added to the applicable Industry specifications.

·  Auditor candidate interviews were scheduled as required.

·  Presentation draft for Auditor training will be addressed in topic 11.0.

·  Oversight audits participation of the Primes were scheduled.

·  Wire EDM tab was added to the NM Matrix spreadsheet as required.

·  Laser machining spreadsheet was split in cutting and drilling as required.

·  AC7116 draft checklist was revised as required.

5.0 SIGNIFICANT PARAMETER UPDATE – CLOSED

List of parameters requiring metallurgical testing or retesting if NM parameters are changes. Processes including EDM and Wire EDM, LBM and Laser Drilling, ECG and ECM were updated by several primes.

ACTION ITEM: Rick Sovich will additionally split the ECM matrix into electrochemical machining and electrochemical drilling. (DUE DATE: 1-Aug-2011)

ACTION ITEM: Rick Sovich will follow up with all the Primes that have incomplete information in the NM Matrix. (DUE DATE: 1-Aug-2011)

6.0 PRIME OVERSIGHT REVIEW – CLOSED

5 audits were observed from February to June 2011:

·  Honeywell – Jindrich Ziegelheim – SEKO EDM, Czech Republic – meets all requirements

·  Boeing – K.T. Quader – Metal Improvement, Santa Ana, Shot peen – meets all requirements

·  Spirit AeroSystem – Angelie Vincent –Sonica NMF America, Shot Peen – meets all requirements

·  Bell Helicopter – Greg Sylverston –Metal Improvement Dallas- Shot Peen –meets all requirements

·  Boeing – K.T. Quader –Abrasive Finishing Co, Shot Peen –meets all requirements

7.0 AC7116 REVISION REVIEW – OPEN

The Task Group reviewed the base document, as well as the 4 slash sheets. All unresolved comments were resolved by voice vote and several questions were revised and to be re-balloted.

ACTION ITEM: A new ballot will be sent out, listing only the revised questions. (DUE DATE: 15-Jul-2011)

8.0 NEW PROCESS SURVEY – OPEN

Rick Sovich queried those present, as to the interest in developing new Checklists or new methods for existing checklists for the NMSE Task Group. Medium interest was expressed for Tumble Peening. Low interest was expressed for Test Methods, Laser Ablation, and Laser Marking however since Laser marking was once an included method in the AC7116 checklist, the Task Group has requested to review it at the next meeting. Two Task Group Members had an interest in the potential for a new checklist for Laser Drilling of Thermal Barrier Coatings and formed a Sub-team.

ACTION ITEM: Rick Sovich will research and present the previous Laser Marking checklist in the Pittsburgh meeting. (DUE DATE: 17-Oct-2011)

ACTION ITEM: A Sub-team including Alex Pohoata, Paul Woolley and Rick Sovich was formed to investigate and make a recommendation of a new checklist or new section to an existing checklist for Laser Drilling of Thermal Barrier Coatings. (DUE DATE: 17-Oct-2011)

9.0 SUPPLIER / PRIME ROUNDTABLE – OPEN

Rick Sovich presented an issue from a recent audit, Almen Strip burrs. Strip samples with typical burrs were provided by a strip manufacture for the Task Group to assess. The Task Group was concerned with the apparent non-conformance with the AC7117 referenced specification J442 requirement of no burrs on almen strips and will develop guidance for Nadcap auditors on the subject. The Task Group also instructed the Staff Engineer to craft a letter to all Nadcap Surface Enhancement suppliers warning of the presence of burrs on almen strips.

The 3 suppliers present did not have any other items to discuss.

10.0 NEW BUSINESS OPEN SESSION – OPEN

There was no new business for the open session.

11.0 AUDITOR TRAINING DEVELOPMENT – CLOSED

Reviewed Auditor “overall ratings”, as well as the detailed “supplier comments” for all of the NM & SE audits dating back to January 2010 to assess potential training topics.

The following Prime’s have agreed to provide auditor training: Boeing & Rolls Royce plc

ACTION ITEM: Rick Sovich will include review of supplier comments for future meeting agendas. (DUE DATE: 17-Oct-2011)

Rick reviewed the “Auditor Best Practices” presentation that he will give during the annual auditor training in October. The Task Group approved the content of the presentation.

Rick reviewed the Auditing Skill Development outline being developed by an NMSE Auditor for the annual auditor training in October. The Task Group like this presentation to be more focused on auditing and investigating skills development however did approve the material presented in the outline.

12.0 NEW BUSINESS – CLOSED

·  NM Significant parameters matrix was decided to be included in the Auditor Handbook when completed.

·  Supplemental Auditor Training. Rick Sovich suggested that periodic regionalized auditor training could be beneficial. This topic is being tabled until the next meeting.

ACTION ITEM: Rick Sovich will include supplemental regional auditor training in the October meeting agenda. (DUE DATE: 17-Oct-2011)

·  Question of Low Pressure alarms was further discussed and tabled until the AMEC-SE Standards committee has addressed the issue.

·  Reviewed NOP008 draft with no comments

·  Burrs on Almen strips. The AMS spec prohibits burrs on Almen strips.

ACTION ITEM: Rick Sovich will craft verbiage for an advisory to suppliers regarding burrs on Almen strips. The verbiage will be approved by the Task Group at the first conference call, before release. (DUE DATE: 1-Aug-2011)

13.0 OCTOBER 2011 AGENDA PLANNING – CLOSED

Agenda was roughed out to a three day meeting and the continuations of separate NM and SE sessions are to be observed as much as possible.

14.0 SUPPLIER WORKSHOP 1 – OPEN

The first workshop session was a focused on internal auditing – a key to excellent audit preparation

15.0 SUPPLIER WORKSHOP 2 – OPEN

The second session was a focus on general preparation for an NMSE Nadcap audit

16.0 SSC PRESENTATION – OPEN

The SSC presentation was given by Rick Scott of Rich Technology International and encouraged all attending Suppliers to attend the SSC Meeting.

17.0 AC7117 REVISION – OPEN

·  Review all of the suggested changes in AC7117/3 and AC7117/4 checklists.

·  The Task Group also reviewed and resolved a list of Asian Supplier comments for AC7117 base document, AC7117/1, AC7117/2, and AC7117/5.

·  Rick Sovich presented a plan to incorporate the Prime Specific Supplement into the existing checklists as a collapsible section. It was explained that due to the minimal amount of supplement questions, this would be a process improvement and enable the Auditor to focus more time on the actual audit criteria. Some Task Group members expressed concern, relative to the expediency of issuing the Audit Checklists, but it was assured that no delay would be caused by the implementation of the existing questions. It was decided to table this idea, until Rick can check with the NMC on the acceptability of this method.

ACTION ITEM: Rick Sovich to discuss the acceptability of a different location for the Prime Supplements with the NMC. (DUE DATE: 1-Aug-2011)

ACTION ITEM: Rick Sovich will include this item in the first Peening teleconference. (DUE DATE: 1-Aug-2011)

·  Alex Pohoata noted that there will be a new AMS specification for Tumble Peening. Once this is issued, he is interested in forming a sub-team to develop a new checklist for the method.

18.0 SSC ACTIVITY REPORT OUT – OPEN

Rick Scott reported the following:

·  There has been a 20% drop in Supplier Voting

·  SSC areas will be addressing: Auditor skills training, Nadcap meeting costs, Certifications no longer have an expiration date, and Contract flow-down.

·  Noted that the SSC would not be addressing ITAR issues.

19.0 PLANNING AND OPS REPORT OUT – OPEN

Angelie Vincent reported on items discussed:

·  Electronic Balloting will go live 7/19

·  Checklist on Demand is still being discussed.

·  Auditor Consistency

·  Merit Criteria

ADJOURNMENT – JUNE 23, 2011 – Meeting was adjourned at 11:30 p.m.

Minutes Prepared by: David McCallister from Pratt & Whitney,

***** 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: / Due date:

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