Introduction to Nadcap/PRI

formally: Nadcap Customer Support Initiative (NCSI)

Revision: 7 Dec 2015

The materials provided online by Performance Review
Institute may be used by Nadcap Suppliers and
Subscribers solely for their internal use, but PRI
requests that attribution be given by placing “©
Performance Review Institute” in the work.

Please be aware that the use of PRI materials for

external publication, distribution or sale is prohibited
unless express written permission has been granted
by PRI. If you have any questions contact Scott
Klavon, Director – Nadcap Program and Aerospace
Operations, sklavon@p-r-i.org, +1 724-772-7111.
2
 Goals
• Educate individuals unfamiliar with the Nadcap process:
 Nadcap – How it works
 Tools and resources available

• Increase awareness of expectations and requirements

in order to:
 Reduce the average number of nonconformances (NCR’s)
 Reduce cycle time (time from audit to accreditation)
 Increase number of Suppliers on Merit program

3
 Contents
 Nadcap Defined
 Nadcap Organizational Structure
 What is a Nadcap Audit?
 Audit Process
 Nadcap Procedures
 ITAR/EAR
 Supplier Merit
 Failure Process
 Preparation Steps
 During and After the Audit
 NCR Responses/RCCA
 Supplier Advisory
 Additional Information
 Nadcap Meeting Information
 Websites

4
 Agenda
• Introduction to PRI and Nadcap

• The Nadcap Audit Process

• Preparation Steps

• During the Audit / Post Audit

• Web Tools & Additional Information

5
PRI is a not-for-profit affiliate of SAE International
PRI administers the Nadcap special processes
accreditation program and PRI Registrar on behalf of its
Subscribing Members and industry

Nadcap created by aerospace Original Equipment

Manufacturers (OEMs or Primes) to provide supply chain
oversight and ensure regulatory compliance
Nadcap uses audit management software created and
maintained in-house by PRI Informatics Solutions
(eAuditNet)

Complementary programs, tools, and professional

development services created by PRI to support Nadcap

6
 Nadcap Defined

• The leading, worldwide cooperative program of

major companies designed to manage a cost
effective consensus approach to special
processes and products and provide continual
improvement within the aerospace industry.

7
PRI/Nadcap Organizational Structure
PRI Board
of
Directors
TASK GROUPS
 Aerospace Quality Systems (AQS)
- AC7004
 Chemical Processing
 Coatings
 Composites Nadcap
 Conventional Machining as a Administrative
Management
Special Process Staff
 Elastomer Seals Council (NMC)
 Electronics
 Fluid Distribution Systems
 Heat Treating
 Materials Testing Laboratories Supplier
 Metallic Materials Manufacturing
 Measurement & Inspection Support
 Non Metallic Materials Committee
Manufacturing
 Non Metallic Materials Testing
 Nonconventional Machining
 Nondestructive Testing
 Sealants,
 Surface Enhancement
 Welding

8
 Nadcap Subscribers
• 309th Maintenance Wing-Hill • Eaton Aerospace Group • Thales Global Services SAS
AFB • Embraer SA • Triumph Group Inc.
• AgustaWestland • Honeywell Aerospace • United Technologies
• Air Force • Israel Aircraft Industries Corporation
• Alenia Aeronautica SpA • Latecoere – Hamilton Sundstrand
• Aerojet Rocketdyne • Liebherr-Aerospace SAS – Goodrich
• Avio SpA • Lockheed Martin Corporation – Pratt & Whitney
• BAE Systems – Military Air • MTU Aero Engines GmbH – Pratt & Whitney Canada
Solutions (MAS) • Northrop Grumman – Sikorsky Aircraft
• BAE Systems Corporation • Volvo Aero
• The Boeing Company • Parker Aerospace Group • Eaton Aerospace
• Bombardier Inc. • Raytheon Company • GE Aviation
• COMAC • Rockwell Collins, Inc. • General Dynamics (Gulfstream)
• Defense Contract Management • Rolls-Royce Corporation • General Services
Agency (DCMA) • Rolls-Royce PLC Administration (GSA)
• EADS Corporation • SAFRAN Group • GKN Aerospace
– Airbus • Sonaca • Hawker Beechcraft Corporation
– Airbus Military • Spirit AeroSystems • Heroux Devtek Inc. (Landing
– Eurocopter • Textron Inc. Gear Division)
– Astrium – Bell Helicopter • Mitsubishi (Aircraft Corp &
– Cassidian Heavy Industries)
– Beechcraft
– Aerolia – Cessna Aircraft Company
– Premium Aerotech – Textron Systems
9
 Supplier Support Committee (SSC)
Mission: Our goal is to represent the Supplier community and work with the Nadcap Management
Council (NMC) to enhance the effectiveness and economical value of the Nadcap program for the
mutual benefit of Suppliers and Subscribers.

SSC Programs/Activities:
• Mentoring Program - Dedicated to assisting those Suppliers who are new to the process and/or
those needing assistance with navigating through the Nadcap system by providing names and
contact information of experienced Nadcap Suppliers. If you would like to work with a Mentor,
please send an email to NadcapSSC@p-r-i.org.
• Supplier Survey – Biennial Customer feedback survey
• SSC Task Group Representatives - Act as a liaison between the SSC and the Task Group and
can advise you on Task Group related inquires.

Nadcap Supplier Support Meeting:

The SSC sponsors several face-to-face sessions at the Nadcap meetings. The Supplier Orientation &
Tutorial provides an overview of the Nadcap program, presented by a Supplier; the SSC meeting is a
forum for discussion and report-out on important issues for Suppliers; and there is also an informal
Question & Answer session where you can meet PRI Staff. Check the meeting agenda for details.

If you would like to receive any additional information on SSC activities, please email
NadcapSSC@p-r-i.org .

10
 Agenda

• Introduction to PRI and Nadcap

• What is a Nadcap Audit?

• The Nadcap Audit Process

• Preparation Steps

• During the Audit / Post Audit

• Web Tools & Additional Information

11
 What is a Nadcap Audit?
• A thorough assessment for compliance to a Nadcap
checklist and Customer requirements
 Conducted by an expert in the commodity
Auditors are chosen by the Task Group

• Audit is not a Quality Systems (QS) Audit!

 Technical audit focused on the specific commodity requirements
 QS related aspects only specific to the commodity e.g. review of
calibration requirements for NDT equipment

12
 General Focus Audit
Does the supplier define the process employed for the calibration of inspection, measuring
Calibration: and test equipment type, unique identification, location, frequency of checks, check method,
acceptance criteria and the action to be taken when results are unsatisfactory?

NDT Heat Chemical

Treating Processing

Technical Focus Audit

Are the FPI dryer ovens Are furnaces used for Is measuring and test equipment used to
calibrated every three heat treating Aluminum control or monitor the control of a process
Calibration: months at multiple points parts surveyed at the (within parameters) maintained in a calibration
across the usable range? required tolerance and system compliant with ISO10012-1? (I.e.
temperature range? temperature gages, conductivity meters,
voltmeters, rectifiers)

NDT Heat Chemical

Treating Processing

13
 Checklists Supplemental
Checklist

Core
Checklist

Slash Sheet
Checklist

Supplemental
Checklist

14
 Begin the Process: Initial Steps
• Go to eAuditNet (www.eAuditNet.com)
• Click on “Get Quote” button
• If you are an existing user, you can log
in and go through the steps to request
a quote
• If you are a new user, you will need to
register in the system and then go
through the steps to request a quote

• Schedule Audit

• Prepare!

15
Nadcap Audit Process – Nadcap Accreditation
1 2 3 4

PRI Audit Auditor

Suppliers Request Audit Scheduled Assigned

7 6a

9 8 6 5

Task Group PRI Technical Audit

Accreditation Staff Review Completed
Approval

16
 Automatic Scheduling
• When the Task Group grants Nadcap accreditation for a
company, eAuditNet is updated and the accreditation is listed
on the online Qualified Manufacturers List (QML)

• At the same time, the next Nadcap accreditation audit

(reaccreditation) for the same commodity will be
automatically scheduled by eAuditNet. 85% of audits are
auto-scheduled!

• Please verify the dates and contact the Scheduling

Department within 21 days of any changes. – IMPORTANT,
a reminder will NOT be sent

17
 Automatic Scheduling – More Details
• When an audit is auto-scheduled, it may be necessary to
accept the Supplier Agreement and designate if there is ITAR
and/or EAR (EC-LR/Restricted) work involved
• Log onto eAuditNet, click on Supplier Audits. Under “Agreements
Accepted” a list of audits where agreements are not accepted will
appear. Click on “Accept Agreement” and complete the acceptance
• Under ITAR/EAR, select “Specify” for the audit which needs the
Export Control Status designating and indicate ITAR/ and or EAR
(EC-LR/Restricted) status accordingly

• The designation of the ITAR/EAR status must be completed

prior to every audit. REMINDERS WILL BE SENT!

18
 Nadcap Documents
• PD 1100 – Nadcap Program Requirements
 The requirements for implementing the Nadcap industry consensus-based accreditation
program

• OP – Operating Procedures
 Documents detailing the specific procedures by which Nadcap operates. These documents
are administered by PRI, and are approved by the Nadcap Management Council.
Example: Audit Failure, Merit, Supplier Advisories, etc

• IMAPP – Industry Managed Accreditation Program Procedure

 Document detailing specific procedures by which PRI/Nadcap Staff operates. These
documents are in accordance with Operating Procedures and administered and approved by
PRI.
Example: Balloting, record retention, internal audit, etc

• Forms
 Forms used to gather or transmit information. These are referenced within the Operating
Procedures and administered and approved by PRI.
Example: s-frms (Scheduling – preliminary questionnaires)
t-frms (Task Group – advisory response form, audit checklist template)

19
 Information available on-line
www.eAuditNet.com
• Resources/Documents/Public Documents
 Change of address sheet (t-frm-11)
 eAuditNet Supplier Guide & Pre & Post-Audit Tutorials
 Audit Handbooks
 Miscellaneous Task Group reference and training documents such as Task
Group Meeting / Symposium presentations, Rolling Action Item List (RAIL),
Pyrometry Reference Guide, etc
• Nadcap Procedures and Forms
• Checklists
www.p-r-i.org
• Nadcap, Supplier Info
 SSC page – Purpose, mentoring, what happens at SSC meetings and more
 PRI/Nadcap - Supplier Perspective
 eAuditNet – For Suppliers
 Professional Development – eQuaLearn Training Courses

Check both sites often – updates made frequently

20
Export Controlled* Materials and Information
• The US government has determined that certain products,
processes and technical information must be controlled.

• The documents which control this are:

 ITAR – International Traffic in Arms Regulation
 EAR – Export Administration Regulations

• Exports can occur by seeing or discussing controlled

material in addition to obtaining copies of the material
*Throughout this presentation reference to “restricted items”, refers to materials, products, technical data,
software, and technology which require licensing or to which other restrictions apply as per the ITAR
or EAR regulations.

21
 Export Controlled Materials & Information
• The Nadcap process uses both Unrestricted and Restricted personnel
(Auditors and Staff Engineers) on Nadcap audits

• Unrestricted auditors are either US citizens or green card holders

 US citizen auditors (Unrestricted) are allowed access to EC-LR
materials anywhere in the world without a license

• Restricted auditors are all others

 Restricted auditors are not allowed access to EC-LR/Restricted
materials anywhere in the world unless they are listed on a
license

• Suppliers must know the status of the PRI personnel & keep any Export
Controlled material away from Restricted/Unlicensed personnel
 Auditor status can be found in eAuditNet next to Auditors name
for assigned audit
 The status of the Audit Report Reviewer is located on the Audit
Summary page and can be seen once the audit is assigned

22
 Supplier Responsibilities
• Determine whether you have material, products,
technology or information which requires a license or is
otherwise restricted by the ITAR or EAR.

• Contact your customers to be certain.

• If you have product, information or any other materials

restricted by the ITAR or EAR, you must indicate such by
answering the ITAR/EAR question “YES” after accepting
the supplier agreement when the audit is scheduled. This
alerts PRI Scheduling as to whether ITAR/EAR controlled
work exists – and guides the assignment of the auditor.

23
 Supplier Responsibilities (Cont.)

• General information on Export Control can be found in

eAuditNet (Public Documents) and on the Supplier page of
the Nadcap website (www.p-r-i.org)

• Suppliers cannot post or reveal any technical details on

EC-LR/Restricted parts in response to any findings in
eAuditNet including attachments
• eAuditNet contains a warning notice for audits identified as
ITAR/EAR, when suppliers respond to findings (see next
screen)

24
Supplier Responsibilities (Cont.)

25
 Supplier Responsibilities (Cont.)

• Beginning March 16, 2015, all program participants are asked to

forward all restricted data which must be sent to any unrestricted PRI
representative in association with a Nadcap audit to the following email
address: restricteddata@p-r-i.org
• In the subject line of the email message, the following information must
be included:
– Audit Number
– Intended PRI recipient and/or Nadcap Commodity-
• Failure to adhere to this procedure could result in the sender’s audit
data being lost and/or a delay in audit processing time.
• For general information on export control regulations, please visit the
following web pages:
– https://www.pmddtc.state.gov/
– http://www.bis.doc.gov/

26
 OP 1106 Accreditation Term
• Supplier term of accreditation begins in conjunction with the audit
date, not the issue date of the certificate.

• Accreditation terms are tied to the Nadcap quarterly cycles

• Reference OP 1106 (available on www.eAuditNet.com)

Audit Month Accreditation Expiration

September, October, November January 31
December, January, February April 30
March, April, May July 31
June, July, August October 31

27
 OP 1111 Supplier Merit
• The Supplier Merit Program awards reduced scope and/or extended
frequency between audits to Suppliers based on length of
participation as a Nadcap Accredited Supplier, number and severity of
recorded non-conformances, and Supplier cycle time

• A supplier undergoes a minimum of three audits (one initial and two

reaccreditation audits) before 18 month accreditation may be
considered

• Following two audits with an 18 month frequency, 24 month extended

frequency may be considered

• Each Task Group shall reach consensus on supplier’s eligibility for

participation in the Supplier Merit program

• Supplier merit is visible on the QML

28
 Supplier Merit Table
18-Month Criteria 24-Month Criteria
Number of audits 2nd Reaccred Audit 2 Consecutive 18-month
accreditations
No Non-Sustaining Corrective Current and 1 previous audit Current and 1 previous audit
Action
No Verification Corrective Action Current and 1 previous audit Current and 1 previous audit
(VCA) Audits
No Product Escapes or Type Current and 1 previous audit Current and 1 previous audit
P/C Supplier Advisories*
Cumulative Supplier No more than 14 Days No more than 7 Days
Delinquency
Number of Findings No more than 50% of Major NCRs No Major NCRs
and 60% of total NCRs per failure
threshold
Other Any justifiable reason identified by Any justifiable reason identified by
Task Group Task Group

*Supplier Advisories – ref OP 1109

Type P = Potential Impact, Type C = Confirmed Product Impact
29
OP 1111 Appendix B

30
Metric: Supplier Merit Status
 OP 1110 Failure Process
• Modes of Failure:
 A - Supplier stops audit
 B – Excessive number of findings
 C - Severity of findings
 D - Too many review cycles to complete
 E – Nonresponsiveness by Supplier

• Criteria are not automatic failure points (except Mode A)

• Only 2% of all audits conducted in 2014 resulted in failure.

• Specific criteria determined by Task Group and listed in OP

1110 Appendix A.

32
 OP 1110 Failure Process
Criteria Examples – Modes B & C
Criteria is reviewed
annually by the Task
Groups.

Please see eAuditNet

for the current criteria
located in OP 1110.

33
 OP 1110 Failure Process Criteria

If an audit meets criteria:

• Per OP 1110, PRI Staff notifies the Commodity Task
Group via Audit Failure Ballot. Task Group will review and
determine if the audit review process should be stopped
and the audit is failed
If an audit is failed:
• Risk Mitigation activities will begin
– The audit NCRs are still work, but accreditation is not granted
– If risk mitigation is stopped, Supplier must appeal to start the
risk mitigation process again
– If risk mitigation is not done, re-entry audit cannot be
scheduled for 24 months
• Company must demonstrate corrective actions to the
auditor on site at the time of the new audit
34
 Agenda
• Introduction to PRI and Nadcap

• The Nadcap Audit Process

• Preparation Steps

• During the Audit / Post Audit

• Web Tools & Additional Information

35
Relationship Between Audit Documents

AUDIT
HANDBOOK
Industry AC7XXX
(if available)
Standards AUDIT
Clarify
& CRITERIA Instructions
Prime + and
Requirements Job Audits Prime (Customer)
specification
requirements

Obtain and download the audit checklist

and audit handbook PRIOR to your audit!

36
 Quality System Approval
• Before receiving a Nadcap special process accreditation,
the company quality system must be approved:
• Nadcap recognized quality systems approvals:
 AS/EN/JISQ 9100 and AS/EN 9110 quality system approvals
performed by approved registrars - listed in the IAQG OASIS
database (www.iaqg.org/oasis). Some Product groups require
AS9100
 ISO/IEC 17025 for testing laboratories (AC7101), must cover
the Nadcap scope of accreditation and be from an approved
ILAC accreditation body
• If you have neither of these, you will need a Nadcap AQS
audit to AC7004 or AC7006 (labs) to support the special
process accreditation
• Refer to PD 1100 and OP 1104
37
 Quality System Approval (Cont’d)
• Suppliers scheduling an initial Nadcap audit shall provide PRI a
recognized quality system certification valid through the last day of the
scheduled process audit prior to the time the audit is entered into
eAuditNet or an AC7004 assessment audit shall be scheduled, unless
the TG requires more than AC7004
• For reaccreditation audits, where no existing recognized quality system
approval exists, Suppliers shall have two options:
 a minimum of 90 days prior to the audit start date schedule an
assessment to AC7004, unless TG requires more than AC7004

 provide PRI a valid Quality System accreditation certificate no later than

60 days following the end of the Nadcap audit
• Suppliers failing to provide a valid quality system accreditation
certificate to PRI by this date shall have the process audit automatically
failed without further notice

38
 Job Audit
• A job audit is a step by step review of the special process on actual
hardware evaluating how the customer requirements are met, using the
Nadcap checklists.

Each special process family will have a certain number of job

audits to be witnessed. Each Task Group has their own
requirements, be sure to review the audit checklist for specific
details

• Schedule the Nadcap audit when able to perform as many of the job
audits as possible

 Work with the scheduling department (internal and PRI)

 Can affect scope of the accreditation
 Paper audits may be used but only when absolutely necessary
and as agreed by the Task Group
NOTE: If clarification is needed, contact the Staff Engineer
39
 Common Findings
• Job Audits
 Customer flowdown
 Lack of shop discipline – inform your personnel!
 Lack of documentation/Objective evidence
 Data transfers
• Processes requiring approvals not approved (i.e., NDT Techniques
or other frozen process)
• Specification compliance (i.e., frozen process doesn’t meet
specification or AMS 2750 compliance)
• Parts cleaning not in accordance with requirements
• Testing including periodic

40
 Common Findings
Common findings refers to Non Conformance Reports (NCR’s)

• AQS (Aerospace Quality System)

 Purchase orders not containing all the necessary information
 Calibration issues (certificates, methods used, etc)
 Lack of document control (wrong revision levels)
 Lack of follow-up on corrective actions
 Internal audits not being performed per schedule

• CP (Chemical Processing)
 Shop paperwork missing information (part, test piece requirements,
etc.)
 Solution Analysis (log sheet, reviews)
 Process non-conformances (operator compliance issues; solutions not
at correct temperature when processing, plating current is not equal to
the required current, paint is not mixed for required time, etc.)

41
 Common Findings
• COMP & NMMT (Composites and Non-Metallic Materials Testing)
(Data available on eAuditNet via Meeting presentation folder) Top nonconformances
by checklist paragraph are included in the Staff Report that is posted on eAuditNet
after each Nadcap meeting under the Composite and Non Metallic Materials specific
Meeting Presentations folder.
• AC7118
 11.3.2 Are documented work instructions available to the operator and does the
procedure(s) accurately reflect the manufacturing process? (Including the proper
sequence)
 12a-g.2.1 Do the specification/drawing/design requirements and revision on the
purchase order match the received material?
• AC7122
 1.3 - The laboratory has facilities capable of meeting the applicable temperature
and humidity requirements.
 24.1 - Each page of the test report is numbered "page __ of__", and has unique
identification traceable to the job and laboratory identification
• AC7122/1
 2.1 - Temperature and humidity requirements are observed.
 2.2 - The relative humidity is less than 60% (except for in-process testing of raw
material manufacturers)

42
 Common Findings
• CMSP (Conventional Machining as a Special Process)
 Not detailing the coolant nozzle layout and positioning
 Not sufficiently detailing the procedure for cutting fluid
maintenance
 Not proceduralizing all items which the checklists explicitly
requires
 Not ensuring the correct tool is in use
 Not detailing the equipment the part is to run on

43
 Common Findings
• FLU (Fluids)
 Procedure does not address requirements, Non-Compliance
to procedure requirements, Failure to record required data
 Lack of Auditing and Control of Sub-Contractors
 Documentation incomplete, errors, operations not signed off
 Calibration Issues, equipment not in calibration system, out
of tolerance conditions not evaluated, expired calibrations,
scope of outside calibration services
 Inadequate purchase order review, flow down of purchase
order requirements

44
 Common Findings
• HT (Heat Treating)
(Data available on eAuditNet – Public Documents / Heat
Treating / Data folder)
 System Accuracy Tests (SAT’s) performed on temperature
control and recording devices
 Calibration records demonstrating conformance to AMS2750
 Calibration frequency and accuracies of equipment and
thermocouples
 Non-Sustaining (Repeat) findings

45
 Common Findings
• MTL (Materials Test Lab)
 Missing Detailed Written Procedures
 Equipment Calibration and traceability (Weigh scales, micrometers,
reference standards, Hardness Standards, Mechanical testing
Alignment, etc.)
 External Proficiency Testing/Internal Round Robin Testing
(Participation, Frequency, Operator/Machine)
 Internal Audits / Corrective Action system

• NDT (Non Destructive Testing)

(Data available on eAuditNet – Public Documents / NDT / Data folder)
 Level 2/Level 3 practical exams (Does the candidate document the
results of what was detected? Is a check sheet used by the responsible
level 3 or delegate?, etc.)
 Records for the training, qualification and certification of NDT
personnel
 Penetrant system performance test not done in conjunction with photo

46
 Common Findings
• SEALS (Elastomer Seals)
 Calibration Issues: Post cure oven calibration does not
address 9 thermocouples and range of use
 Records/Procedures/Work Instructions: Not following
procedure, procedure does not address, record retrieval,
inadequate work instructions
 Calibration Related: Equipment not in the calibration system
 Operator Training: Operators not trained effectively on the
operations being performed
 Material Identity: Material not properly identified and
protected from contamination

47
 Common Findings
• SLT (Sealants)
 Calibration Issues: Expired calibration, Missing calibration labels, equipment not
in system, out of tolerance condition not evaluated, instrument identified as
reference only but used for product acceptance, Calibration Lab not 17025 or on
the suppliers approved vendors list
 Internal Procedures: does not address, procedures not being followed, lack of a
written procedure. Not working to latest document revisions
 Weight for tack free test not in calibration system
 Chart Recorders, not calibrated, pens not working, charts not changed
 Viscometer Calibration does not address the range of use

• WLD (Welding)
(Data available on eAuditNet -Public Documents / Weld / Supplier info)
 Has the supplier demonstrated compliance to the welding schedule?
 Does the welding schedule address all customer requirements?
 Is the welder/operator qualification complete and up to date for the work being
performed?
 Does the supplier have a documented welder qualification procedure?
 Are pre-weld preparations defined and in accordance with customer requirements

48
Best Practices for Nadcap Success

• Strengthen your internal audit program – Use the

Nadcap checklists! Include Job Audits every time.
Understand the interpretation and expectations
• Download the Nadcap checklist and perform a thorough
and complete self-audit
 Record, by question, where in the system the requirement is
documented
 Record, by question, where the objective evidence of
compliance is in the system
 If you cannot write down where in the system the
documentation is located and what you will show the auditor
– the checklist answer is No!
 Perform a full set of Nadcap job audits
49
Best Practices for Nadcap Success
• Confirm all personnel understand the role they play in
making the audit successful

• For reaccreditation audits - Review all NCR’s (Majors /

Minors) from the previous audit to ensure corrections
taken are sustaining
• Use the tools available on www.eAuditNet.com
 Tutorials where available
 Audit Handbooks where available
 Checklists

50
 PRI Staff Engineer
• The PRI Task Group Staff Engineer has commodity
specific knowledge and expertise
 Review audit report packages. Make recommendations for
accreditation to the commodity Task Group
 Qualified auditors – Understand the process
 Work intimately with the commodity Task Groups – Understand
requirements, interpretations and expectations
 When necessary, use their expertise before and after your audit

51
 Staff Engineer Advice
• It is the companies’ responsibility to ensure all
requirements are met
 Do not shift responsibility to others for non compliances or
assume everything is acceptable because it was believed to be
acceptable in the past
 Understand the interpretation of the requirements and/or Task
Group expectation. Contact the Staff Engineer if uncertain

• Ensure compliance throughout all of the company

documents
• Auditor will check for complete compliance

52
 More Staff Engineer Advice

• Conflict between the checklist - comply with the customer

requirement or pick the most stringent? If uncertain,
contact customer or PRI

• Multiple customer requirements will require a more robust

system

• The specification is the requirement. Procedures must

meet all requirements in the specification, with supporting
evidence as required by the checklists

53
 Agenda
• Introduction to PRI and Nadcap

• The Nadcap Audit Process

• Preparation Steps

• During the Audit / Post Audit

• Web Tools & Additional Information

54
 Scope Verification
• At the beginning of the opening / introduction meeting
(in-briefing), the auditor will log onto eAuditNet.com and
request the supplier representative review the scope of
the audits to ensure accuracy and make any changes
accordingly prior to the audit commencing
 Electronic ‘sign-off’ process
 Once the audit begins, generally no changes can
be made to the scope of accreditation
• The auditor does not determine the scope, that is the
responsibility of the company. If uncertain, verify with
your customer

55
 Daily Briefings
• At the end of every audit day, the auditor should conduct a
daily briefing to summarize the progress and review any
non conformance reports (NCR) generated during the day
 Inform key company personnel (if required)
 Promotes open communication between the company and auditor
 Allows the company time to obtain further clarification or objective
evidence that may invalidate the NCR
 Purpose is not to excessively debate or argue about an issue with
the auditor. Problems occur, contact appropriate Staff Engineer
 Review any outstanding items that needed to be addressed to answer a
checklist questions
 Discuss the next days agenda to ensure personnel are available
 Minimize time necessary at the final out-briefing

56
 Exit Meeting
• An out-briefing or exit interview with Supplier Management
personnel shall be conducted to:
– review non-conformances
– obtain commitments for corrective actions
– explain the other aspects of the Nadcap process
 Schedule top management to attend
 Make certain the company understands any NCR’s written – ask
questions if you do not understand - this is your chance to ensure
the finding will be written clearly

57
 Exit Meeting
• Review the accreditation process requirements and
expectations before the auditor leaves
 Highlight key Nadcap procedures to review
 NCR Corrective Action outline, response time frames
 eAuditNet process
 Supplier Feedback
• Open communication between the Supplier and Auditor is
important. Again, if problems occur, contact the appropriate
Staff Engineer

58
 NCR Classifications
Major Nonconformance:
• The absence of, or systemic breakdown of, the Process Control and/or
Quality Management system Or
• Any non-conformance where the effect impacts or has the potential to
impact the integrity of the product
Examples: incorrect process parameters, missing inspections or processing
steps, failure to record required data, missed or out of tolerance calibration;
result from failure to implement a corrective action from the previous audit

Minor Nonconformance:
• Any single system failure or lapse in conformance with the applicable
standard or audit criteria
Examples: paperwork oversights, minor changes to procedures for clarification

Refer to Resources – Procedures and Forms – Operating Procedures - OP 1103 in

www.eAuditNet.com

59
 After the Auditor Leaves
• Feedback is invaluable to the process – Nadcap is a cooperative
program
 When a company submits their NCR responses (within 21 calendar
days) they are prompted to complete the Supplier Feedback online
questionnaire
 When there are O NCRs, the company is required to complete the Supplier
Feedback within three business days
 Complaints must be submitted in writing and will be addressed
independently of the audit review process

• There is an appeals process for NCRs, Staff Engineer decisions, and

Task Group decisions
 Refer to OP 1113 for further details

60
61
 NCR Review

• NCR responses are closed when the company

meets the expectation of the commodity Task
Group
 The Task Group expects a complete and thorough
assessment of the NCR by the supplier
 Immediate corrective action taken
 Root cause
 Impact to hardware
 Action taken to prevent recurrence
 Training

62
 NCR Review
• Provide objective evidence
 Procedure changes, control check log sheets, calibration
certificates, immediate and long term training, etc

• Immediate corrective action is not the action taken to

prevent recurrence

• Failure to close NCR’s delays accreditation, adding cycle

rounds and days

63
Between Audit & Accreditation
Yes

1. Supplier Submits 2. Staff Review of Additional

Information
Corrective Action Supplier Corrective
Requested
Responses Action Responses

No
Yes
Additional 3. Task Group
Information Review of Audit
Requested
Package

No

4. Accreditation

64
 Supplier Advisory
• The purpose of the Nadcap Supplier Advisory is to notify
Nadcap Users of issues with conformance of products,
services, or quality systems of Nadcap Suppliers

• Three types of Supplier Advisories exist

 Type P – Potential for Product Impact
 Type C – Confirmed Product Impact
 Type F – Failed Audit

• Supplier Advisories are located and controlled in eAuditNet

65
 Supplier Advisory (Cont’d)
• The Supplier has seven (7) calendar days from issuance of a Nadcap Supplier
Advisory (type P or C only) to provide a response. The mandatory Supplier
response shall include at a minimum the following elements: a positive
statement regarding the investigation of the potential or confirmed product
impact; a confirmation that all customers have been notified; and a statement of
rationale based on the Supplier’s investigation as to the impact to the product.
Form t-frm-06 shall be attached with appropriate responses. Responses will be
noted under the actual advisory located in eAuditNet. Note: Contractual
requirements for Customer notification earlier than seven (7) calendar days may
apply.

• Nadcap accreditation may be suspended or withdrawn as a result

• May affect other commodity accreditations held

• If believed to be systemic and affecting the Quality Systems approval, the AQS
Task Group will review and where necessary notify the applicable
Certification/Registration Body (CRB)

• Refer to OP 1109 for more information

66
 NCR Response Submittals
• Auditor submits the audit within 3 business days from the
last day of the audit
• Staff Engineers have 3 calendar days to perform ITAR
review
• Initial responses are due within 21 calendar days from the
date the Staff Engineer completes ITAR review and puts
into Supplier review status
 Submit in eAuditNet, in accordance with Requirements for
Corrective Action Response

Refer to Resources – Public Documents – eAuditNet – User Guides/Tutorials – Supplier Guides – Post
Audit Tutorial on www.eAuditNet.com

• For completeness of the audit report, additional information

or clarifications may be requested by the Staff Engineer
67
 Response Requirements
Help available:

www.eAuditNet.com
- A link to Response Requirements is attached to the NCR
The link is located right above the Supplier Response box

Also: www.p-r-i.org/nadcap
- Supplier Info – Post Audit Assistance

Also: www.eQuaLearn.com to register for RCCA training

68
 Corrective Action Response
Requirements
Reply to your NCR in the Supplier Discussion for each NCR
in the format below and addressing each item in the ‘Your
Reply’ section of the eAuditNet Supplier response forum for
each NCR
 Immediate Corrective Action Taken (Containment Actions)
 Root Cause of Nonconformance
 Impact of all Identified Causes and the Root Cause
 Action Taken to Prevent Recurrence
 Objective Evidence is required on ALL findings
 Effectivity Date

69
Example – The Non Conformance
Requirements: AMS-QQ-P-416, Type 1, Cl. 3 - paragraph
4.6.2 - Adhesion
AMS-QQ-P-416, Table 3

Identified Nonconformance:
a. Router required to perform an adhesion bend test. Supplier
bended test coupons to about a 60% angle and reviewed for
adhesion failures.
Specification requires a bend to fracture test.
b. Sampling plan for visual examination did not meet the AMS-
QQ-P-416, Table 3 requirement.

70
 Immediate Corrective Action
Define Immediate Corrective Action Taken
What action was taken following the issue being discovered
during the audit?
• Did you stop the problem from continuing?
• Did you contain the problem found?
• Did you notify Customers of suspect parts/hardware?
• Did you review other parts/processes/documents affected?

These actions address the immediate or direct cause of the NCR only

71
Immediate Corrective Action (Cont’d)
Define Immediate Corrective Action Taken:
Example of an Unacceptable Immediate Corrective Action:
The procedure was modified
Example of an Acceptable Immediate Corrective Action:
• Receiver instructed to use the Test Matrix (F-751-001) to verify correct
flow down of testing requirements
• Receiver and QC personnel trained on the use of the Test Matrix (F-
751-001)
• Verification of testing flow down to job traveller added to the PO Review
Checklist (F-722-002)
• All travelers are being revised to this format (emailed separately due to
ITAR). New software beta testing to begin Weds, 04/11/2013 with
detailed inspection requirements, including sampling plan based on
specifications, directly as part of job traveler.
72
Root Cause Analysis Flow Chart

Document
Team

Root Cause: the LAST

Document
Causes cause in the chain!

Document
C/A
Re-Address
Corrective
Action
Document
Follow-Up

No

73
 Root Cause
Define Root Cause of the Nonconformance:
Investigate all causes contributing to the nonconformance using fish bone
diagrams, 5-why analysis or similar tools. The root cause will be the last
logical cause in the chain

Think you got it? Try one more!

Only the identified Root Cause should be included in the response (Do not
write a thesis). Supplemental information to support the cause analysis
may be included as objective evidence if necessary

74
 Root Cause (Cont’d)
Define Root Cause of the Nonconformance:
Example of an Unacceptable Root Cause:
We have been audited by many customers in the past. This has never
been a problem and our requirements have been found to be acceptable

Example of an Acceptable Root Cause:

Internal procedure MAP-722-001, did not require the use of the test matrix
to flow down testing requirements.
PO review was not required to verify proper flow down of testing
requirements.

75
 Impact of Identified Causes
Define the Impact of all Identified Causes and the Root
Cause:

What impact did the nonconformance actually have?

 Consider
 Were any other parts / processes affected?
 Were any affected parts shipped to the customer?
 Was the customer contacted?

76
 Impact of Identified Causes (Cont’d)
Define the Impact:

Impact to Hardware:

Example of an Unacceptable Impact Statement:

No Impact

Example of an Acceptable Impact Statement:

Specification violation – potential impact. Notification sent to customers for
all jobs plated in the last six months. Copies of notification letters attached.

77
Actions Taken to Prevent Recurrence
Define the Actions Taken to Prevent Recurrence: What are
the steps taken to prevent this problem from occurring again?

• What is the long term action to prevent recurrence?

• Can only be addressed when the true root cause is known

• Do not rush, consider the effectiveness, feasibility, suitability to the

company, and the company's budget

• Remember, non-sustaining Corrective Actions (CA) become MAJOR

findings. By not addressing CA’s adequately there is a potential for a
non-sustaining finding on the next audit. This will affect your Supplier
Merit

78
Actions Taken to Prevent Recurrence (Cont’d)

Define the Action Taken to Prevent Recurrence:

Example of an Unacceptable Action Taken:

The procedure was revised

Example of an Acceptable Action Taken:

• Internal procedure MAP-722-001, revised to require use of test matrix to flow
down testing requirements on traveler.
PO Review Checklist (F-722-002) revised to include verification of testing flow
down against the test matrix.
• Procedure MAP-021-001 has been revised to call out both the bend to fracture
and sampling plan requirements.
• All personnel have been trained to revised form and procedures.
• The test matrix also points to the specific locations in MAP-021-001 for the
sampling plan requirements. The new software going into beta testing the week
of 4/16/2013 allows specific sampling plans for each specification.
• Follow-up internal audits will be performed to ensure the correct use of the form
and that the software is adequate for out needs.
79
 Objective Evidence
Define and Attach Objective Evidence:

• What information can be provided to demonstrate the RCCA process applied to

the NCR?
 Objective evidence is required for Major & Minor NCR’s except minor NCR’s accepted
(not closed) onsite by the auditor
 Note: It is expected that the supplier clearly define the root cause corrective action
taken. If a procedure is changed, clearly specify what the change was

• Don’t forget to identify the specific actions taken to resolve the

nonconformance(s), (e.g., exact text of procedure change, text of stamp to be
ordered, etc.)
 Objective evidence should be attached electronically in www.eAuditNet.com or
submitted by U-fax
 A U-fax directory is located in the Public Documents section of www.eAuditNet.com
 Contact the Staff Engineer with any questions

• If you change or create a procedure, implement a new system or method, perform

training, propose audits, develop new checklists - SHOW THIS. It may prevent
another review cycle
REMEMBER: Do not attach information that discloses Export Controlled details.

80
 Objective Evidence (Cont’d)
Define and Attach Objective Evidence:
Objective Evidence:

Example of Unacceptable Objective Evidence:

See attached revised procedure

Example of Acceptable Objective Evidence:

• Revised F-722-002 PO Review Checklist
• Training record to F-722-002
• Revised MAP-722-001 Order Entry/Receiving Instructions
• Training record to updated procedures
• Notification Letters NCR2.zip - Compressed file containing copies of all
notification letters delivered. (via email)
• Affected Customers.xlsx - Table containing list of all affected customers and
related POs. (via email)

81
Corrective Action Response Requirements (Cont’d)

Effectivity Date:

When will the corrective actions be completely implemented?

(Accreditation generally cannot be issued until after this date.)

82
 Key Points to Consider
• Supply all the necessary objective evidence, e.g. copy of revised
procedure, procedure approval, copy of revised process control log,
evidence of training, etc
• Respond directly in eAuditNet
 Word documents / NCR templates / other attachments containing the
RCCA response is not acceptable. Provide the response directly in
eAuditNet. Attachments are for objective evidence only

• Address every aspect of the Root Cause Corrective Action (RCCA):

 Immediate corrective action taken
 Root cause
 Impact to hardware
 Action taken to prevent recurrence
 Objective evidence

• Provide information within the defined time frame

83
 Corrective Action – More details

• Call the Staff Engineer!

 If you need clarification on a request for more information, a
phone call may save you an additional review cycle
 If you will not be able to meet the procedural time frames for
responses...extensions can not be granted but communication
about WHY a date is missed is important

84
 If Your Response is Not Accepted
• You have 7 calendar days to respond to the Staff Engineer
request for additional information
• If the Staff Engineer details a specific request:
 Review and comply with the entire request. Your response will
not be accepted until all items are addressed
 Only address what is being asked from the Staff Engineer. Do not
resend the whole RCCA response
• In the event of a generic rejection, i.e., “Readdress Root
Cause”
 Review the Requirements for Submittal of Corrective Action
Responses and make certain you are complying with these
requirements
• Call the Staff Engineer for clarification

85
 Response Due Dates
• Response extensions are not given, however the company is allowed
a limited number of cumulative late days that can be used through the
life of the audit report package. Late days typically used:
 Allow a more thorough response to be provided
 Key personnel on vacation or sick
 Awaiting equipment installation, calibrations, etc
 Training of personnel
 After 30 late days, audits are processed per OP 1110 (Audit
Failure)
 Per OP 1111 (Merit Program)
 18 month accreditation cannot be achieved if more than 14
cumulative late days
 24 month accreditation cannot be achieved if more than 7
cumulative late days

86
 How to Avoid Repetitive NCR’s!
• Involve all personnel that will have the responsibility to fix, implement
and monitor the corrective actions
• Issue notifications throughout all company departments when
policies/procedures are changed as a result of corrective action
responses
• Ensure that more than one person within the company is totally familiar
with past and present Nadcap audits and NCR’s
• Create a process to ensure Corrective Actions for all NCR’s - major or
minor - have been implemented and are monitored, as part of the
internal audit process. Management involvement and monitoring is
mandatory! (AS9100)
• Do not attempt quick fixes - even for minor non conformances. If quick
fixes are accomplished there should be a process within the company
on how these are accomplished and what the limitations are

87
 Agenda
• Introduction to PRI and Nadcap

• The Nadcap Audit Process

• Preparation Steps

• During the Audit/Post Audit

• Web Tools & Additional Information

88
 Pre-Assessment Audit
• Companies can schedule a pre-assessment audit using a
Nadcap auditor BEFORE the actual Nadcap audit

• All the data from the audit will be left with the company

• The only findings which will be sent to Primes are findings

which may have significant potential for impact to hardware

• Contact PRI Scheduling and/or review OP 1108 for more

details

89
 Using eAuditNet Effectively
• Keep email address current to ensure you receive
important emails related to your audit

• If there is a change in company information, complete

t-frm-11. eAuditNet under Resources / Documents /
Procedures and Forms / Nadcap Controlled Forms / tfrms
• Do not reply to automated emails received from eAuditNet
– there are contacts listed in the email

• For eAuditNet Support, refer to the Public Documents

section for User Guides or contact the Help Desk at +1 724
772 8679 or via email at eAuditNetsupport@p-r-i.org

90
92
 Nadcap Meeting Information
• Available at www.p-r-i.org
• Minutes & Agendas
 Keep up with Task Group activities
 Participate in Task Group decisions

• Plan to attend Open Meeting – Suppliers are always

welcome
• Closed meeting times for User Members only are
necessary to discuss proprietary supplier company
accreditation issues such as appeals, findings, etc

93
 SSC Meeting Information
• Operates independently of the Task Groups – focus on
overall issues common to suppliers – not technical or Task
Group specific

• Attend the Supplier Support Committee (SSC) meeting to

learn about ongoing projects

• Get involved – Join the SSC! Volunteers Needed!

94
95
 Important Websites

www.p-r-i.org
www.eAuditNet.com
www.eQuaLearn.com
www.eQuaLified.org

96