Nonconventional Machining & Surface Enhancement

NONCONVENTIONAL MACHINING & SURFACE ENHANCEMENT

OCTOBER 2012

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
* / 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.

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.

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)

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.

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.

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.