Surface Enhancement

NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2010 UNCONFIRMED MINUTES OCTOBER 18 – 22, 2010 PITTSBURGH MARRIOT CITY CENTER PITTSBURGH, PENNSYLVANIA

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, OCTOBER 18 – THURSDAY, OCTOBER 21, 2010

OPENING COMMENTS – OPEN

1.0 CALL TO ORDER / QUORUM CHECK

The Nonconventional Machining & Surface Enhancement Task Group (NMSETG) was called to order at 8:00 a.m., 18-Oct-10.

A quorum was established with the following representatives in attendance:

User Members/Participants Present (* Indicates Voting Member)

NAME COMPANY

* Scott Patterson Goodrich Corporation Chairperson * Angelie Vincent Spirit AeroSystems Inc. Vice-Chairperson * Dave McCallister Pratt & Whitney Secretary * Silvia Baeza Triumph Group Inc. * Marc Belanger Bombardier Inc. * Zeljko Caliza Goodrich Corporation Allan Cooley 309th Maintenance Wing-Hill AFB Mark Covert Honeywell Aerospace * David Day GE Aviation * William Fitzgerald Northrop Grumman Aaron Havlovic Cessna Aircraft Company * Glen Heide The Boeing Company Ron Kramer General Dynamics Corp. * Serge Labbé Héroux Devtek Inc. * Susan Margheim Rockwell Collins Inc. * Gudrun Muehlbauer MTU Aero Engines GmbH * Jeremy Phillips Cessna Aircraft Company * K.T. Quader The Boeing Company Doug Scheidt GE Aviation Laurie Swensen 309th Maintenance Wing-Hill AFB Debbie Vogel Triumph Group Inc. Michael Walker Spirit AeroSystems Inc. John Woodward Honeywell Aerospace * Paul Woolley Rolls Royce plc Grzegorz Wryk Goodrich Corporation

Other Members/Participants Present (* Indicates Voting Member)

1 NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2010 NAME COMPANY NAME

Jeffrey Almeyda Master Metal Finishers Tomohiko Ashikaga Mitsubishi Heavy Industries Ltd. Ken Chromik H & H Aero, Inc. Steve Connally Metal Improvement Company Steve Ganske Precise Machining & Manufacturing Dave Jones Nex-Tech Processing Alexander Klyuch Blades Technology Ltd. Scott Kronabetter Micro-Tronics Kyle Lindsey Danville Metal Stamping Co. Inc. John Lopez E. M. E. Inc. Rich Ludrosky Duke Manufacturing/PM Machine * Edward Mayer Meyer Tool Inc. Mike Nosek Micro-Tronics David Osenar Pako Inc. Sandeep Rana GF AgieCharmilles * Tim Scarlett Danville Metal Stamping Co. Inc. * Rick Scott Rich Technology International Toshiyuki Serizawa Ishikawajima-Harima Heavy Industries Co. Dawn Stokes PTI Industries Inc. Gigi Streeter Barnes Aerospace * Yoshiomi Sukesada Asahi Kinzoku Kogyo Inc. Melissa Ulle Duke Manufacturing/PM Machine

PRI Staff Present

Jennifer Kornrumpf Richard Sovich

1.1 Review of Nadcap Meeting Rules and Guidelines

A review of Antitrust Policy, Personal Code of Ethics and Conflict of interest were reviewed by Scott Patterson.

1.2 NMSE Vision Statement was reviewed by Scott Patterson.

2.0 REVIEW NM SIGNIFICANT PARAMETER MATRIX RECAP – OPEN

After the June 2010 Singapore Nadcap Meeting, Gudrun Muehlbauer from MTU Aero Engines and Mark Gleason of GE Aviation created a spreadsheet to list significant parameters for EDM & LBMR processing. To create this spreadsheet, each Subscriber was asked to list those parameters requiring metallurgical testing/retesting to verify conformance to Subscriber requirements. During the meeting, an additional column was added to note if Subscriber sign-off is required.

Rick Sovich presented this spreadsheet. For EDM, GE Aviation, MTU Aero Engines, and UTC-Pratt & Whitney had given their input. For LBM, MTU, UTC-P&W, and Honeywell had given their input. During the meeting, Doug Scheidt from GE Aviation provided update for GE requirements for the matrix.

ACTION ITEM: Doug Scheidt will provide suggested wording for LB cutting versus LB drilling in the SP Matrix spreadsheet. (DUE DATE: 31-Dec-2010)

ACTION ITEM: NMSE Primes are to provide input to Gudrun for the SP Matrix before the next meeting. (DUE DATE: 28-Feb-2011)

2 NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2010

ACTION ITEM: Rick Sovich will contact each Prime to identify all specifications supporting the SP Matrix. (DUE DATE: 28-Feb-2011)

ACTION ITEM: Gudrun Muehlbauer and Mark Gleason will update the Significant Parameters matrix to include ECM and ECG pages. (DUE DATE: 28-Feb-2011)

3.0 AC7116 REVISION – OPEN

Rick Sovich led a lengthy review of the AC7116 revisions that were just released. Some of the ballot comments were reviewed and all Task Group actions will be updated onto the checklist for the final affirmation ballot.

ACTION ITEM- Rick Sovich and Dave Jones will review information in eAuditNet, to determine if the information in para 3.2.1 of the AC7116 Rev B draft is redundant. (DUE DATE: 28-Feb-2011)

4.0 CALL TO ORDER / QUORUM CHECK – CLOSED

4.1 A reminder of Personal Code of Ethics, Conflict of Interest, Antitrust, and NMSE Vision Statement were reinforced by Scott Patterson

4.2 Approval of Previous Meeting Minutes

Motion made to approve the minutes from the June 2010 Nadcap meeting. Motion Passed.

The minutes from June 2010 were approved as written.

4.3 Call for New Members / Review Current Roster

No new member requests were raised at this meeting.

As part of the NMSE RAIL, we have removed some members from the Current Roster, due to non- participation.

ACTION ITEM: Rick Sovich will contact each removed Prime to encourage participation in the Task Group (DUE DATE: 28-Feb-2011)

5.0 NMC METRICS – CLOSED

Rick Sovich reviewed the following NMC metrics:

 NMSE auditor capacity. Overall capacity is high and the only area that may become a concern is potential spot shortages with ITAR restricted auditors for Asia and Europe.  NMSE Certificates Issued  Total Supplier Cycle Time  Total Reviewer Cycle Time  Percent of Eligible Processors with Merit  Task Group Performance and Participation  Sector Auditors Required vs. Capacity  Staff Delegation Tracking Forms reviewed for Joe Barr, Marcel Cuperman, Sarah Jordan, and Rick Sovich.

ACTION ITEM: Update the Delegation Tracking Form to indicate Delegated or Non-Delegated. (Sarah Jordan and Marcel Cuperman are not delegated) (DUE DATE: 28-Feb-2011)

6.0 RAIL REVIEW – CLOSED

All RAIL items were reviewed and closed.

ACTION ITEM: K.T. Quader requested that actions as a result of concerns or recommendations made from Oversight Audits, should be included as a regular meeting agenda item for future meetings (DUE DATE: 28-Feb- 2011)

Jeremy Phillips indicated a concern about a particular supplier that continually declines an oversight audit. Under the current system rules, oversight is not mandated. It was advised that the Customer Prime can still utilize contractual access outside of the Nadcap audit. Jeremy Phillips will discuss with his NMC representative and Rick Sovich will raise the concern at the Nadcap Meeting review to PRI management.

ACTION ITEM: Rick Sovich will raise the Task Group concern of Supplier’s that continually refuse Prime observers during Nadcap audits and report out at next meeting. (DUE DATE: 28-Feb-2011)

7.0 NMSE AUDITOR SCREENING – CLOSED

Jeremy Phillips gave presentation, on behalf of team members Sarah Jordan and Alex Pohoata They evaluated the way other Task Groups handle testing of auditors, prior to being hired. TG’s included NDT, Welding, and Heat Treat.

RECOMMENDATION: Team recommends separate tests for NM and SE, prior to being interviewed. Test should include 30-40 questions on basic theory and auditing principles. Also suggested that 6-8 questions for each slash sheet be included and 70% correct to pass with Staff Engineer discretion. It was not determined if the test was to be open or closed book.

ACTION ITEM: Scott Patterson and Angelie Vincent formed the Auditor Screening Subteam to pursue the recommendation of June 2010 RAIL item #1 - and report out at next meeting. The Auditor Screening Subteam will recruit other members going forward. (DUE DATE: 28-Feb-2011)

ACTION ITEM: Auditor Screening Subteam to submit scope and timeline for development. (DUE DATE: 28-Feb- 2011)

8.0 DEEP DIVE – AUDITOR CONSISTENCY – LOSS OF MERIT – CLOSED

Bill Fitzgerald analyzed two suppliers that lost merit. He reviewed the initial audit, and subsequent audits Bill recommends this analysis be sanitized for the minutes and be revisited at a later date to analyze more data.

9.0 SUBSCRIBER OVERSIGHT AUDITS REPORT-OUT – CLOSED

Six oversight audits were reviewed and concerns noted.

ACTION ITEM: Rick Sovich to include NOP 007 – Guidelines for conducting an Oversight Audit on the next agenda. Individual TG members need to discuss with their NMC Representative, to determine their individual company policies. (DUE DATE: 28-Feb-2011)

ACTION ITEM: Rick Sovich will review the Oversight Audit concerns and discuss with auditors and update the Prime observers raising the concerns. (DUE DATE: 28-Feb-2011)

10.0 REVIEW OF AUDITOR PERFORMANCE – CLOSED

10.1 Rick Sovich reviewed Auditor Performance. He explained how the “average rating” is calculated and entered into eAuditNet. All auditors were in the range of 5.4 to 6.0, with 6.0 as the maximum possible

4 NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2010 rating. The internal training plan was updated and three SE auditors have received training are ready to interview to become an NM auditor and one NM auditor is ready to interview to become an SE auditor.

11.0 FEBRUARY 2011 AGENDA – CLOSED

A draft agenda was developed. Initial draft is for 3 days, but could be extended to 4 days if necessary. Surface Enhancement is scheduled to meet on the first day, combined topics on day two and Nonconventional Machining on day three.

12.0 NEW BUSINESS – CLOSED

12.1 Scott Patterson asked the TG if we would be able to complete all our business in 2 annual meetings, instead of 3 annual meetings. The TG overwhelmingly believed that 3 annual meetings are necessary.

A request to consider Task Group certifications for approved auditors was raised. After a brief discussion, it was decided that the TG did not want to pursue this.

Rick Sovich raised the concern about Task Group members using “Accepted with Comments” as a way to record non-actionable notes such as “not a current supplier”. It was requested that the Task Group use the “accepted” designation for non-actionable notes.

The value of the “50 day+ report” was discussed and the Task Group concluded that the audits were being run very efficiently and the report was no longer necessary for NMSE. It was decided that the report was to be discontinued.

12.2 TG discussed whether to replace the NMC Supplier Voting Representative.

ACTION ITEM: Scott Patterson will review the applicable procedure for NMC Supplier Voting Representatives and discuss further actions with the Staff Engineer. Report out at the next meeting. (DUE DATE: 28-Feb-2011)

12.3 Paul Woolley of Rolls Royce brought up a question concerning a deviation for wet glass peening. The Task Group decided to change checklist question AC7117/2 para 9.3.6 to include “N/A”.

12.4 Mark Covert of Honeywell announced that he is the new AQS Liaison for NMSE, replacing David Day.

ACTION ITEM: Rick Sovich and Scott Patterson will provide an orientation for the new AQS representative (DUE DATE: 01-Feb-2011)

13.0 SSC AND PLANNING & OPS REPORT OUT – CLOSED

Scott Patterson reviewed the highlights of the Planning & Ops Committee

A new meeting format was discussed with no particular objections.

In the absence of Dave Jones and Rick Scott, the SSC report was presented by Rick Sovich.

14.0 NEW BUSINESS – OPEN

It was suggested to document the quorum check for each session. It was decided that a one-time documentation of quorum was sufficient, due to the history of the Task Group which has never failed to reach quorum at a Nadcap meeting.

Bill Fitzgerald made a recent audit observation regarding part damage to holes using hard tooling (needle nose pliers) to remove plugs to protect holes from damage. A recommendation to add a question to prevent damaging the part while applying or removing masking.

5 NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2010 ACTION ITEM: Bill Fitzgerald to provide proposed question and any supporting specification reference, to be included in the next checklist revision of AC7117. (DUE DATE: 31-Jan-2011)

Angelie Vincent notified the TG, of a question brought up by an SE auditor, regarding adequate lighting.

ACTION ITEM: Each Prime was asked to review their shot peening specification for a requirement for minimum lighting requirements during Product Acceptance Inspection and provide information to Angelie Vincent. (DUE DATE: 31-Jan-2011)

15.0 FACILITATION FEEDBACK REVIEW – OPEN

The Facilitation Feedback form was reviewed and completed by the Task Group.

16.0 AC7117 REVISION (POTENTIAL QUESTIONS FROM INDUSTRY SPECS AMS 2430 & AMS 2432) – OPEN

16.1 Angelie Vincent presented a summary of the Checklist Questions from Section 5 for validity to NMC vision. All reviewed questions were compliant to the NMC Checklist Vision of at least one Prime Specification or an Industry Standard.

TG decided to clarify question 5.2.3, regarding protection of Almen fixtures from damage and corrosion. Since there is no industry specification to back this requirement up, it is appropriate to put the clarification into the Auditor Handbook.

ACTION ITEM: Add clarification of Almen block protection into the Auditor’s Handbook for AC 7117 Rev A. para. 5.2.3. (Following the methodology of the new revision of AS9100) (DUE DATE: 28-Feb-2011)

AMS 2430 Gap Analysis - Bill Fitzgerald created a list of questions, based on AMS 2430 rev R, with the intent of reviewing them against the current checklists.

ACTION ITEM: Gap Analysis Subteam to evaluate new specification revisions of AMS 2430, AMS 2432 and any other relevant specifications that changed in the last year, against the AC7117 Checklists. The Subteam is led by Bill Fitzgerald and members include Angelie Vincent, Scott Patterson, Dave McCallister and Rick Sovich. (DUE DATE: 31-Jan-2011)

ACTION ITEM: Identification of non-value added checklist questions Subteam was formed to evaluate and recommend removal of questions, based on historical nonconformance data and potential risk to process. The Subteam members are Dave Jones and Steve Connally. (DUE DATE: 31-Jan-2011)

ACTION ITEM: Rick to supply list of all findings that have never generated an NCR by paragraph number. Subteam to examine the questions to see if they need to be reworded or removed. Sub-Group to recommend revisions to specific questions, and send to Rick Sovich. Subteam to report out at Feb Meeting (DUE DATE: 28- Feb-2011)

17.0 SUPPLIER TRAINING – Training was provided for attending Suppliers.

ADJOURNMENT – OCTOBER 21, 2010 – Meeting was adjourned at 12:00 p.m.

Minutes Prepared by: David McCallister from Pratt & Whitney, [email protected]

***** 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 Who is responsible: Due date: revision: