Omni William Penn Hotel s3

FASTENERS OCTOBER 2006 UNCONFIRMED MINUTES 17-19 OCTOBER 2006 OMNI WILLIAM PENN HOTEL PITTSBURGH, PENNSYLVANIA, U.S.

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.

TUESDAY, 17 OCTOBER 2006 (CLOSED SESSION)

1.0 AUDIT REVIEW

The 1st Pilot Audit results were discussed and reviewed.

2.0 IMPLEMENATION STRATEGY

The Primes continue to work with their respective organizations to establish timelines on the implementation and flow-down of Fastener Task Group requirements to manufacturers and distributors. A status will be presented at the next meeting in Redondo Beach, California, U.S.

WEDNESDAY, 18 OCTOBER 2006 (OPEN SESSION)

3.0 OPENING COMMENTS

3.1 Call to Order/Quorum Check

The Fasteners Task Group meeting was called to order at 11:00 a.m. A quorum of qualifying members was established.

3.2 Introductions

The following representatives were in attendance:

User Members Present Demaree Faulkner Rolls Royce Corp. (Indianapolis, IN) Mike Ferguson United Space Alliance (Cape Canaveral, FL) Scott Frazier - Vice Chairperson Boeing (Long Beach, CA) Edward Lu Honeywell (South Bend, IN) Laurie Strom Honeywell (Phoenix, AZ) Steve Spahr GE Aviation (Cincinnati, OH) Jim Traverso - Secretary Honeywell (Roanoke, TX) Harry Willis Cessna Aircraft (Wichita, KS) Paul Woolley Rolls Royce plc. (Derby, UK)

Note: Scott Frazier served as Chairperson since John Sattler, Chairperson, was unable to attend. 1 FASTENERS OCTOBER 2006 Other Participants/Members Present Gregoire Aguilar Alcoa Fastening Systems (Toulouse, France) Jean-Francois Chevalier Lisi Aerospace (Saint Ouen l’Aumone, France) Brad Crandall Heartland Precision Fasteners (New Century, KS) David Eshleman The Young Engineers (Lake Forest, CA) Ed Johnson Alcoa Fastenening Systems (Torrance, CA) Rick Kuhns Bristol Industries (Brea, CA) Richard Landt PCC-SPS Technologies (Jenkintown, PA) Michel Leger Alcoa Fastening Systems (St. Coshe, France) Larry Phipps Alcoa Fastening Systems (Fullerton, CA) Barry Reid PCC-Shur-Lok Corporation (Irvine, CA) Alan Shu Alcoa Fastening Systems (Torrance, CA) James Thomas Sonic Industries, Inc. (Torrance, CA) Bob Whitley Wesco Aircraft (Valencia, CA) Gabriella Zele Alcoa (Nemesvamos, Hungary) ` PRI Staff Present Jeff Conrad PRI Staff (Warrendale, PA) Phil DeHennis PRI Auditor (Philadelphia, PA) Con Murren PRI Auditor (North Ayrshire, Scotland)

3.3 Routing of Attendance List

The attendance list was routed for signatures.

3.4 Approval of Previous Meeting Minutes

The minutes from the 18-20 July 2006 Fasteners Task Group Meeting was presented and reviewed. A motion was made for approval, seconded and all were in favor with no disapprovals. Therefore, the minutes were approved as written.

Meeting minutes are available on the PRI web site at www.pri- network.org.

A new format for tracking of action items has been implemented. A Rolling Action Item List (RAIL) is being maintained which will easily track the action items assigned by quarters, as well as percentage completed and archiving. The RAIL will be updated for each Nadcap commodity by the 15th of each month and posted under the Public Documents application on eAuditNet. This will allow for easy access for up to date information regarding the status of action items.

For details, refer to the RAIL located on the last page of these minutes.

2 FASTENERS OCTOBER 2006 The action items from the previous meetings were reviewed as follows:

July 2006: - Action Items 1 - 10 were closed. - Action Item 11 remained open.

April 2006: - Action Items 1, 6, 7 and 8 were closed.

January 2006: - Action Items 1, 3 and 5 remained open.

October 2005: - Action Items 3 and 5 remained open.

Specific to Action Item 6 from the July 2006 quarter, Jim Traverso, Honeywell, has accepted the position of Fasteners Task Group Liaison to the AQS Task Group.

4.0 STAFF REPORT

Notes of interest from the Nadcap Executive Strategic Planning Board (NESPB), Nadcap Management Council (NMC), Nadcap Planning and Operations Meeting, Task Group News of Note, and PRI Staff News were presented.

Specific items of interest to the Fasteners Task Group included:

 2006 Audit Projections = 6 (2 Americas, 2 Europe, 2 Asia) o First pilot audit conducted 22-24 May 2006 in U.S. o First pre-assessment conducted 7-10 August 2006 in U.S. o Second pilot audit scheduled 28 November – 1 December 2006 in U.S.  PRI is formalizing documentation (procedures, forms, eAuditNet) in preparation for implementation of the Fasteners Task Group  NMC Standardization Sub-Team agreed to standardize NCR definitions of Major and Minor  Nadcap Customer Support Initiatives (NCSI) are conducted to aid new suppliers in audit preparation o US, European and Prime specific sessions detailing initial audits, re-accreditation audits o Commodity specific sessions are also being held  2007 Audit Projections = 15 (8 Americas, 4 Europe, 3 Asia)

5.0 FASTENERS TASK GROUP STATUS UPDATE

5.1 Charter

The Fasteners Task Group Charter was reviewed. This details background/history, mission, customers/stakeholders, expected results/due dates, process steps/milestones, status and leadership.

3 FASTENERS OCTOBER 2006 5.2 Milestones

Milestone 1, Defining Scope/Task Group Members, is complete.

Milestone 2, Standard Development, continues with the piloting of the Nadcap Audit Criteria AC7113 and AC7113/1 through AC7113/5. The September 2006 drafts are being utilized for the 2nd pilot audit.

Milestone 3, Selection of Auditors, is complete. See agenda item 5.3 for more auditor specific information.

Milestone 4, Pilot Audits, is on-going. The first pilot audit and first pre-assessment are complete. The second pilot audit is scheduled for 28 November – 1 December 2006. See agenda item 6.0 for more pilot audit information.

Milestone 5, Publish Audit Criteria and Implement, can be completed by the end of the 1st quarter of 2007.

5.3 Auditors/Auditor Training

During the development phase the task group will utilize three (1 U.S., 1 Canadian, 1 European) of these auditors to attend meetings, review checklists, develop the auditor handbook and conduct the pilot audits. Two auditors were utilized for the first pilot audit. One auditor was utilized for the first pre-assessment. Two auditors will be utilized for the second pilot audit.

Annual Fasteners Auditor Training was conducted on Monday, 16 October from 8:00 a.m. – 5:00 p.m. and Tuesday, 17 October 2006 from 8:00 a.m. – 12:00 noon. Topics included Program Status Overview, Prime Flow-Down Requirements, Sequencing and Sampling Plans, Heat Treatment of Fasteners, NDT of Fasteners, Materials Testing of Fasteners and Chemical Processing of Fasteners.

The Primes and Manufacturers participating in the auditor training included:  Jean-Francois Chevalier, Lisi-Aerospace  Demaree Faulkner, Rolls-Royce Corp.  Mike Ferguson, United Space Alliance  Scott Frazier, The Boeing Company  Larry Phipps, Alcoa Fastening Systems  Barry Reid, Shur-Lok  Harry Willis, Cessna Aircraft  Paul Woolley, Rolls-Royce plc.

4 FASTENERS OCTOBER 2006 5.4 Ballots

Four task group ballots have been completed. The required two valid ballots were obtained to move forward with the pilot audit phase. The next task group ballot will take place after all of the comments resulting from the pilot phase are incorporated. This is estimated to take place in December 2006 which will allow for any comments to be resolved during next meeting in January 2007.

6.0 PILOT AUDITS

The first pilot audit was successfully conducted 22-24 May 2006. The audit was conducted by two PRI/Nadcap Fasteners Auditors and was observed by 8 Primes representing The Boeing Company, Cessna Aircraft, GE Aviation, Honeywell, Raytheon Aircraft, Rolls-Royce Corp, Rolls-Royce plc. and 1 PRI staff member.

The first pilot audit tested the following audit criteria:  AC7113, Nadcap Audit Criteria for Fasteners  AC7113/1, Nadcap Audit Criteria for Fastener Manufacturers  AC7113/4, Nadcap Audit Criteria for Chemical Processing of Fasteners  AC7113/5, Nadcap Audit Criteria for Materials Testing of Fasteners

It was verified that the special process audit criteria for Chemical Processing and Materials Testing are 1-day audits per NESPB’s direction. It was also verified that the AC7113 and AC7113/1 can be either a 2-day or 3-day audit based on the fastener manufacturing scope of the audit. This will be further tested and verified during the next pilot audit.

The first pre-assessment pilot audit was conducted 7-10 August 2006. The audit was conducted by one PRI/Nadcap Fasteners Auditor and observed by 5 Primes representing The Boeing Company, GE Aviation, Pratt & Whitney, Raytheon Aircraft and Rolls-Royce plc.

The first pre-assessment pilot audit tested the following audit criteria:  AC7113, Nadcap Audit Criteria for Fasteners  AC7113/1, Nadcap Audit Criteria for Fastener Manufacturers  AC7113/2, Nadcap Audit Criteria for Heat Treatment of Fasteners  AC7113/3, Nadcap Audit Criteria for Nondestructive Testing of Fasteners

It was verified that the special process audit criteria for Heat Treatment and Nondestructive Testing are 1-day audits per NESPB’s direction. It was also verified that the AC7113 and AC7113/1 should be a 3-day audit. This will be further tested and verified during the final pilot audit.

The second pilot audit is scheduled for 28 November – 1 December 2006. The audit will be conducted by two PRI/Nadcap Fasteners Auditors and will be observed by at least 3 Primes representing The Boeing Company, GE Aviation, Raytheon Aircraft and 1 PRI staff member. 5 FASTENERS OCTOBER 2006 The second pilot audit will test the following audit criteria:  AC7113, Nadcap Audit Criteria for Fasteners  AC7113/1, Nadcap Audit Criteria for Fastener Manufacturers  AC7113/4, Nadcap Audit Criteria for Chemical Processing of Fasteners  AC7113/5, Nadcap Audit Criteria for Materials Testing of Fasteners

6.1 Audit Criteria Comments

Comments from the 1st pre-assessment audit were reviewed. Agreed upon changes were made to the documents as applicable and will be included in the final ballot.

6.2 Length of Audits

Based on the pilot audits to date, the following is the task group recommendation for the length of the audits based on the scope:

Manufacturer: – AC7113 + AC7113/1 = 3 day audit • + AC7113/2 = 1 additional day • + AC7113/3 = 1 additional day • + AC7113/4 = 1 additional day • + AC7113/5 = 1 additional day Fastener Special Processor: – AC7113 + any one special process slash sheet = 2 day audit • Add one more day for each special process slash sheet

7.0 ADDITIONAL TASK GROUP COMMENTS OF AC7113, AC7113/1-5

All additional comments that were submitted relative to the September 2006 draft of the audit criteria were discussed. Changes agreed to by the task group were incorporated and will be included in the next drafts that will be developed after the final pilot audit.

The content of AC7113 and its relation to other quality system requirements (e.g. AS/EN/JISQ9100, AC7004) were discussed. A question was raised regarding the potential duplication of questions. It was clarified that the goal of the system questions included in AC7113 were not to duplicate existing quality system requirements, but to concentrate on areas specific to the fasteners industry and areas in which the task group feel that further attention needs given. The task group decided that no changes would be made to the AC7113 until after the completion of the second pilot audit. The content of the AC7113 will be reviewed at the next meeting in Redondo Beach, California, U.S.

ACTION ITEM: Larry Phipps, Alcoa Fastening Systems, to gather data regarding quality system questions specific to AC7113 vs. AS/EN/JISQ9100 and AC7004.

6 FASTENERS OCTOBER 2006 A recommendation was made to move the full paperwork job audits, Sections 13a. and 13b., from AC7113/1 to AC7113. The task group decided that no changes would be made until after the completion of the second pilot audit. The location of these sections will be reviewed at the next meeting in Redondo Beach, California, U.S.

A suggestion was also made to add a definition for the term procedure to clarify the documentation requirements during the audit. The task group decided that no changes would be made until after the completion of the second pilot audit. The definition section will be reviewed at the next meeting in Redondo Beach, California, U.S.

The scope and methods that would appear on the Qualified Manufacturers List (QML) was discussed. Additional breakouts for some of the special processes (e.g. for NDT of Fasteners, add Fluorescent Penetrant Inspection and Magnetic Particle Inspection) were recommended and will be further tested and evaluated after the completion of the second pilot audit. The QML listing will be reviewed at the next meeting in Redondo Beach, California, U.S.

8.0 NTGOP, FASTENERS APPENDIX DEVELOPMENT

The draft of the Nadcap Task Group Operating Procedure (NTGOP) -001, Appendix X, was presented and reviewed. This document includes specific items to the Fasteners Task Group, including but not limited to accreditation term, supplier merit, audit failure and staff delegation.

One of the requirements that will need to be finalized after completion of the pilot audit phase Section 10.0, Supplier Delinquency and Failure. The initial criteria for Audit Failure Mode B, Excessive Number of Findings, for consideration are set as greater than forty (40) total nonconformances. This procedure will be balloted to the task group voting membership after the final pilot audit.

Section 12.0, Auditor Interview, was also discussed. The base NTGOP states that the Task Group User members shall interview auditor candidates. A decision needs to be made regarding the participation of supplier’s/manufacturers in this interview process. The pros and cons were discussed and a vote was taken that no changes would be made to the draft. A suggestion was made that as a minimum supplier’s/manufacturers could provide a list of questions the User members could utilize during the interview. This topic will be further discussed at the next meeting in Redondo Beach, California, U.S.

ACTION ITEM: Richard Landt, PCC-SPS Technologies, Barry Reid, PCC-Shur- Lok, and Rick Kuhns, Bristol Industries, to begin drafting technical questions for future auditor interviews.

7 FASTENERS OCTOBER 2006 THURSDAY, 19 OCTOBER 2006 (OPEN SESSION)

9.0 FASTENERS AUDITOR HANDBOOK DEVELOPMENT

No additions were made to the auditor handbook.

10.0 PRIME/SUPPLIER VOTING MEMBERSHIP

The task group voting membership was discussed. As implementation is on the horizon, the formal voting membership will need to be finalized. The task group discussed those that would be classified as User Voting Members, Alternate User Voting Members, Supplier Voting Members and Alternate Supplier Voting Members.

It is forecasted that there at implementation date, there will be at least 8 Prime User Voting Members from the following companies: Boeing, Cessna, Raytheon Aircraft, Pratt & Whitney, GE Aviation, Honeywell, Rolls-Royce Corp. and Rolls-Royce plc.

ACTION ITEM: Mike Ferguson, United Space Alliance (USA), to determine USA role in the Fasteners Task Group.

The number of Supplier Voting Members cannot exceed the number of Prime User Voting Members. Recommendations were taken for those suppliers that may be interested in supplier voting membership.

ACTION ITEM: Richard Landt, PCC-SPS Technologies, and Barry Reid, PCC- Shur-Lok, to determine supplier voting membership recommendation based on PCC affiliation.

11.0 IMPLEMENTATION PLAN

There are required documents that will need to be revised to incorporate the Fasteners Task Group as well as new documentation. These can be in the forms of Nadcap Operation Procedures (NOP’s), Nadcap Internal Procedures (NIP’s), Nadcap Task Group Operating Procedures (NTGOP’s) and internal forms. A thorough review has been conducted and the documents will be revised once the audit criteria is approved and published.

ACTION ITEM: Larry Phipps, Alcoa Fastening Systems, to review s-frm-03, Fasteners Preliminary Questionnaire, and provide any comments or revision recommendations for consideration.

12.0 OPEN DISCUSSION

No open discussion items were presented.

8 FASTENERS OCTOBER 2006 13.0 NEXT MEETING DATE/LOCATION/DEVELOP AGENDA

The next Nadcap meetings are scheduled for the week of 22-26 January 2007 in Redondo Beach, California, U.S.

The Fasteners Task Group will tentatively meet on Tuesday, 23 January through Thursday, 25 January 2007.

The formal agenda will be developed, distributed and will be available on www.pri- network.org. Topics will include results of 2nd pilot audit, resolution of task group ballot comments to AC7113, AC7113/1-5, auditor handbook content and preparation for implementation.

14.0 ACTION ITEM REVIEW/CLOSING COMMENTS

The action items were reviewed and are noted throughout the meeting minutes. Please reference the action item list located on the last page for due dates.

ADJOURNMENT – 3:30 p.m.

Minutes Prepared by: Jim Traverso, [email protected] Jeff Conrad, [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:

9 FASTENERS OCTOBER 2006 Nadcap Division TO-DO-LIST

FAST RAIL 30-OCT-06