Nonconventional Machining & Surface Enhancement

NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

CONFIRMED MINUTES OCTOBER 22 - 26, 2012 OMNI WILLIAM PENN HOTEL PITTSBURGH, PENNSYLVANIA, USA

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 22 – THURSDAY, OCTOBER 25, 2012

OPENING COMMENTS – CLOSED

1.0 CALL TO ORDER / QUORUM CHECK

The Nonconventional Machining & Surface Enhancement (NMSE) Task Group was called to order at 8:00 a.m., 22-Oct-12.

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 Aerospace Vice Chairperson * Dave McCallister UTC- Pratt & Whitney Secretary * Silvia Baeza Triumph Group Inc. * Vincenzo DeRosa Alenia Aermacchi * Bill Fitzgerald Northrup Grumman * Mark Gleason GE Aviation Andrew Heikkinen Bell Helicopter * Glen Heide The Boeing Company * Serge Labbe Heroux- Devtek Marc-Andre Lefebvre Heroux-Devtek * Simon Long Airbus Operations Limited * Dan Loveless Parker Aerospace * Gudrun Muhlbauer MTU * K.T. Quader The Boeing Company Jeffery Robb Cessna Michael Steele The Boeing Company Mike Schmidt GE Aviation * Kenneth Sposato Triumph Group Stanley Trull Honeywell Aerospace * Donald Williams GE Aviation * Paul Woolley Rolls Royce PLC

Other Members/Participants Present (* Indicates Voting Member)

NAME COMPANY NAME Tomohiko Ashikaga Mitsubishi Heavy Industries John Cammett Nadcap Auditor Becky DeGutis SAE International NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

* Dave Jones 3P Processing Inc. SSC Representative Jeffrey Kupis Micro-Tronics Inc. Alexander Klyuch Blades Technology LTD Guy Levasseur Aerosphere Inc. David Osenar PAKO, Inc. Buddy Raderstorf KIHM Metal Technologies * Tim Scarlett Danville Metal Stamping Co. * Dawn Stokes PTI Industries * Yoshiomi Sukesada Asahi Kinzoku Kogyo Inc.

PRI Staff Present

Richard Sovich Mike Graham

1.1 Review of Personal Code of Ethics and Conflict of Interest

A video by Joe Pinto was presented which reviewed Antitrust, Personal Code of Ethics, Conflict of Interest, and Nadcap Operating Rules.

1.2 NMSE Vision Statement was reviewed by Angelie Vincent

1.3 The agenda was reviewed and recently failed audits were added to the closed meeting agenda to facilitate the Supplier who traveled to the meeting and an auditor who was leaving shortly.

1.4 Review of NM Audit #143940 meeting failing criteria at supplier request One non-conventional machining audit was reviewed by the Task Group in detail. The Task Group interviewed the respective auditor Jo Bezant to clarify Task Group member questions about the findings. After careful review, the Task Group unanimously decided that all findings were valid as written and instructed Rick Sovich to process the audit under a failure ballot.

ACTION ITEM: Rick Sovich will process the Task Group reviewed NM audit #143940 under a failure ballot. (Due Date: 15-Nov-12)

1.5 Review of Failed SE Audit #146624 at Task Group request. A failed SE audit was reviewed in detail by the Task Group to determine the Root Cause of the failure. A deep dive was provided by Bill Fitzgerald of Northrop Grumman and analyzed all of the previous audits. The Root Cause appears to have been an insufficient understanding of required elements for job audits that were using demonstration parts. The Task Group reviewed the NMSE Job Audit Selection Guideline and determined that the guidance for this respective area was insufficient and the Guideline needed additional work. The Supplier was very cooperative and provided information as requested.

A subcommittee was formed to review and recommend revisions to the Job Audit Selection Guideline

ACTION ITEM: The Job Audit Selection Subcommittee (Alex Pohoata-Lead, Bill Fitzgerald, and Holger Polanetzki) will review and recommend revisions to the respective guidance and report out at the next Nadcap meeting. (Due Date: 18-Feb-13)

2.0 SEPARATION OF NM AND SE DISCUSSION

A lengthy discussion was held covering pros and cons of separating the NM and SE technologies. The Task Group unanimously agreed to postpone the official request of separation and instead decided to trial a functional separation of the two technologies. The NM and SE trial separation will begin for the February 2013 Nadcap and a final decision to separate will be made in the Oct 2013 Nadcap meeting. If approved, a formal proposal will be developed for submittal to the NMC Steering Committee in the 4th Qtr. 2013. NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

ACTION ITEM: Rick Sovich will coordinate activities to separate agendas for NM and SE technologies. (Due Date: 18-Feb-13)

3.0 NMSE METRICS – CLOSED

Rick Sovich reported on the following:  NMSE Program Cumulative Status of Audits Completed YTD: Total audits are running slightly ahead of projections.  Current NMSE Roster status: Current NMSE Auditor roster appears to be adequate for 2013 audit projections.  Task Group Metrics – NMSE vs. other groups: NMSE was comparable to most other groups and was performing well in supplier merit, cycle time averages which consistently met or exceeded goal. The only concern was a slightly over goal cycle time for initial audits, however since this metric was only based on a few audits, the flag was not a major concern, however the Task Group will keep an eye on this metric over time.  Total Supplier Cycle Time - Reaccreditation: This metric was good for the period and a reflection of a maturing supplier base.  Staff Cycle Time: - Reaccreditation: This metric was good for the period and seemed stable  TG Cycle Time: TG cycle time is remaining consistent.  Merit Eligibility: Merit remained stable at 96% of eligible suppliers. There are approximately 450 suppliers eligible for merit.  Prime participation in ballots: Prime participation for audit balloting was excellent. Most every subscribing prime reviewed audit packages.  Delegation metrics: Delegation metrics were reviewed and remain consistence this quarter at 98% concurrence for Rick Sovich with 90% oversight and 98% concurrence for Joe Barr with 93% oversight.

4.0 NMSE RAIL REVIEW – CLOSED

 Rick Sovich updated circumstance for lapsed audits. It appears to be an isolated incident and additional training was provided to the CSR.  Spanish translation of SE Handbook as shown live in eAuditNet.  Laser Cutting of Composites was tabled and may be addressed at a future meeting.  All other RAIL items were either closed or tabled

5.0 PRIME OVERSIGHT AUDIT REVIEW – CLOSED

One Prime Oversight Audit was reviewed for the period, with no major problems noted:  Audit 144454: John Tattersall by Simon Long.  An auditor from a previous oversight audit concern was asked to attend the closed session and was interviewed by the Task Group. The Task Group was satisfied with the Auditor’s explanation which addressed the concern.  A suggestion to provide a chart showing which auditors have historically been observed was requested as an annual agenda item. The chart can provide guidance, for Prime’s, when they wish to conduct an oversight audit. The NMSE Task Group unanimously approved this suggestion and decided it should be located at a central location such as eAuditNet. NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

ACTION ITEM: Rick Sovich will provide an annual update to the Prime Observation Chart showing which auditors have historically been observed for October meetings. (Due Date: 10-Dec-12)

6.0 AUDITOR REVIEW

Rick presented a chart, showing Auditor comparison called a “red-line auditor” chart. This is the concept that was originally developed by NMSE Task Group in 2006, now fine-tuned and being expanded across all Task Groups.

6.1 Rick reviewed all Auditor Evaluation Feedback from 26-Jun-12 through 20-Oct-12. All supplier feedback was positive.

1.0 CALL TO ORDER / QUOROM CHECK / OPENING COMMENTS – OPEN

1.1 Review of Personal Code of Ethics and Conflict of Interest A video by Joe Pinto was presented which reviewed Antitrust, Personal Code of Ethics, Conflict of Interest, and Nadcap Operating Rules.

1.2 NMSE Vision Statement was reviewed by Angelie Vincent

7.0 CALL FOR NEW PRIME MEMBERS

A call for new members was initiated by Angelia Vincent. The following people requested membership in the Task Group. Each member was verified for previous attendance and approved by unanimous TG and the appropriate forms completed.  Donnie Williams, GE Aviation  Dan Loveless, Parker Aerospace  Vincenzo DeRosa, Alenia Aermacchi  Marc-Andre LeFebvre, Heroux-Devtek

ACTION ITEM: Rick Sovich will submit 4 membership forms (m-frm-01) and Jennifer Kornrumpf will add 4 new voting members. (Due Date: 15-Nov-12)

8.0 NM INDUSTRY SPECIFICATION

Alex Pohoata presented the draft of a new EDM specification from AMEC. Several Primes expressed interest, because they have their own NM specifications. It was explained that the intent of this specification is to establish a baseline document for the industry.

ACTION ITEM: Rick Sovich will send draft EDM industry specification to all registered NM members for comment (Due Date: 1-Dec-12)

9.0 THERMAL BARRIER DRILLING OF HOLES

This item is being tabled, due to proprietary concerns of Primes.

10.0 LASER MARKING SUB-TEAM – OPEN

Alex Pohoata presented a report on laser marking, and 10 questions for an initial checklist. An additional member added to the subcommittee. The subcommittee is now Alex Pohoata- lead, Dave McCallister, Paul Woolley, Gudrun Muhlbauer, Donnie Williams and Tim Scarlett.

ACTION ITEM: Rick Sovich will send the draft Laser Marking checklist to the Laser Marking Subcommittee. (Due Date: 1-Dec-12) NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

ACTION ITEM: The Laser Marking Subcommittee will provide a recommendation for potentially adding this technology to the AC7116/5 checklist at the February 2013 meeting. (Due Date: 18-Feb-13)

11.0 SUPPLIER/PRIME ROUNDTABLE

Grit Blasting as a Special Process: TG and suppliers discussed this topic, relative to the need for a Nadcap checklist. Other TGs cover this process, as part of a larger process: NDT, Chem processing, etc. TG decided that no specific checklist questions are needed. However, Boeing suggested if any Primes have specific concerns, they should add specific questions to their Checklist Supplement.

Boeing suggested TG discuss post peening processing (thermal exposure and metal removal) with the other TGs, to see if there are any controls related to shot peened surfaces. A subcommittee was formed to further investigate: K.T. Quader - lead, Alex Pohoata, Sylvia Baez, Dave Jones, Glen Heide, and Marcel Cuperman.

ACTION ITEM: Rick Sovich will add a Thermal Exposure and Metal Removal subcommittee report out of other controls to monitor Thermal Exposure and Metal Removal of shot peened parts currently existing in other commodities. (Due Date: 18-Feb-13)

ACTION ITEM: Rick Sovich and the Thermal Exposure and Metal Removal subcommittee will set up a conference call with Chem Processing, Coating, Conventional Machining, and HT TG’s. (Due Date: 10-Dec-12)

11.2 AMS 2430 REV S - Alex Pohoata informed the NMSE Task Group and suppliers of a Quality Alert issued 9–Oct-2012. Honeywell is allowing suppliers to work to AMS 2430 Rev R until July 1, 2013. (Due Date: 18-Feb-13)

ACTION ITEM: Rick will issue an Auditor Advisory stating- “for Honeywell orders, supplier is permitted to use AMS 2430 rev R, until July 1, 2013”. (Due Date: 15-Nov-13)

12.0 NEW BUSINESS – OPEN

12.1 Auditor Orientation Program - Rick Sovich presented information on the new Auditor Orientation Program, developed by PRI over the last 6 months. Comments were positive.

12.2 TG recognized Mark Gleason of GE Aviation for his dedication over the years, and particularly for the first few years, when he helped start the NMSE Task Group.

13.0 REVIEW OF AC7117 CHECKLIST REVISION

No interested supplier was present for review, so Supplier Training was immediately started.

14.0 TECHNICAL PRESENTATION – SE

Dr. John Cammett presented 3 technical topics relating to Shot Peening from the NMSE Auditor Training  Industry Specification Update  New SE Technologies (not covered by Nadcap checklists)  Peening Intensity Determination and Confirmation  Historic Perspective on Peening Specifications

15.0 SE INDUSTRY SPECIFICATION REVISION UPDATES

Dr. John Cammett presented a comprehensive review of revision changes to industry specifications and how these changes affect the supplier with respect to the Nadcap checklist. NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

16.0 SSC PRESENTATION – OPEN

David Jones gave the SSC Presentation. The most recent supplier survey was very successful. Actions are being taken, as a result of the survey. The next one will be conducted in 2014. David Jones also reported on SSC initiatives, including the mentoring program, supplier tutorials, and supplier helpdesk. NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

17.0 MEETING MINUTES APPROVAL

Prior meeting minutes were reviewed and unanimously approved as written.

ACTION ITEM: Rick Sovich will update the status of the June 2012 Minutes and post accordingly (Due Date: 10- Dec-12)

18.0 SSC ACTIVITY REPORT OUT

Dave Jones talked about the previous day’s activity at the SSC Meeting and all of the good activities in which the suppliers are engaging.

19.0 PLANNING AND OPS REPORT OUT

Angelie reported the previous day’s activity from this meeting. It was noted that meeting now seems to much less conflict than in the past.

20.0 NEW BUSINESS - OPEN

20.1 RECOGNITION OF TG CHAIRPERSON - Alex Pohoata recommended the TG recognize Angelie Vincent for her leadership in the proposed separation of NM and SE Task Groups.

ACTION ITEM: Rick will submit for recognition award for Angelia Vincent at the Dallas meeting. (Due Date: 10- Dec-12)

20.2 Standardized Demonstration Coupon- TG decided that a standardized test sample design should be developed for the industry. This sample design would enable new suppliers to get qualified to an industry specification. The sample would be developed to incorporate specific requirements of all Nadcap Primes. A subcommittee was formed: Alex Pohoata, Gudrun Muhlbauer, Donnie Williams, Paul Woolley, and Gigi Streeter.

ACTION ITEM: The Standardized Demonstration Coupon Subcommittee will meet to define standardized demonstration coupon and report out at the Dallas meeting. (Due Date: 18-Feb-13)

23.0 SUPPLIER WORKSHOP – OPEN

The following supplier training presentations were provided:  K.T. Quader gave a presentation on Boeing specifications.  Rick Sovich gave presentations on the Top 10 NCRs for NM and SE. Calibration of gages was the #1 finding on both lists. The 2012 Top 10 lists was compared to the 2010 Top 10 lists  Dan Loveless of Parker Aerospace gave a presentation on their EDM requirements  Alex Pohoata of Honeywell gave a presentation on the differences between AS9100 Rev B and Rev C  Marc-Andre Lefebvre of Heroux-Devtek gave an informational presentation on his company and their requirements.

ACTION ITEM: Rick will present the Top NCRs at each Pittsburgh meeting as a finding percentage. (Due Date: 18-Feb-13)

24.0 SMART CHECKLIST – OPEN

Louis Stefanakis gave a presentation on the Smart Checklist.

25.0 NM TECH TOPIC NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

Rick Sovich presented information on DMLS (Direct Metal Laser Sintering)

26.0 NM AND SE SEPARATION PLANNING – OPEN

 Rick Sovich presented an overview, with the pros and cons of separation, and an outline for the necessary steps to take. Several Primes plan to use the same person to support both TGs.  One key concern for these Primes is the potential additional $7000 fee, if using Subscription Plan A.  The NMSE Task Group reviewing all applicable current documents, to see if separate documents will be required for the two groups.  TG decided that the following procedures need to be separated and/or strengthened:  Afrm30 NIP 6-01  NTGOP-001 Appendix XIII. New Appendix will need to be created

ACTION ITEM: Rick Sovich will add an agenda item to discuss NM and SE separation to the February 2013 meeting. (Due Date: 18-Feb-13)

ACTION ITEM: Rick Sovich will prepare a draft of other applicable procedures requiring minimal effort to separate, and distribute to TG. (Due Date: 30-Nov-12)

27.0 NMSE TASK GROUP LEADERSHIP SUCCESSION:

TG unanimously voted for Alex Pohoata as TG Chairman, effective 1-Jan-13. TG unanimously voted for Paul Woolley as TG Vice-Chairman, effective 1-Jan-13.

28.0 INTERIM CONFERENCE CALLS

TG agreed on the following dates for intermeeting conference calls: Monday 12/10 10:00 a.m. EST (all TG) Monday 1/14 10:00 a.m. EST (all TG) Monday 2/4 10:00 a.m. EST (TG Leadership)

ACTION ITEM: Rick Sovich will send out 3 meeting notice for the period meetings. (Due Date: 1-Dec-12)

29.0 ROSTER REVIEW – OPEN

29.1 Rick reviewed roster and TG removed the following individuals:  Rick Scott  Marc Belanger  Cristina Gonzalez-Perez  Windsor Amunden  Nigel Davies  Kaz Hata  Tim Myers  John Woodward  Gary Burns  Jim Kruba  Mike Nosek  Roland Hudon  Neil Tinsley  Patrick Rozzi NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES

 John Hammond  Gary Maxwell  Bob Reynolds  Patricia Wesemer

29.2 The following Voting Members failed to vote on Ballots, however the NMSE TG voted to keep them on the TG:  Airbus Reps  Danville Metal Stamping  Meyer Tool  Microtronic  Northrup Grumman Reps  Rolls Royce Reps  Triumph Reps

29.3 The following Voting Members are being removed as subscribers, due to non-attendance at meetings:  EADS-CASA  Metal Improvement  Rich Technology  Rockwell Collins

ACTION ITEM: Rick Sovich will contact Bombardier and Goodrich concerning replacement of replacement TG members. (Due Date: 10-Dec-12)

30.0 FEBRUARY 2013 AGENDA PLANNING – OPEN

Due to the complexity of the potential split of NM and SE groups, the TG decided to allow Rick Sovich to develop the February 2013 agendas, and review them during the first TG Conference Call.

ACTION ITEM: Rick will develop separate draft agendas for NM and SE technologies. (Due Date: 10-Dec-12)

ADJOURNMENT – 25-OCT-12 – 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: NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT OCTOBER 2012 CONFIRMED MINUTES