Avoid Common Pitfalls: The Top PRI NRCs in Heat Treating
Nadcap accreditation is essential for maintaining high standards in heat-treat operations and quality systems. Learning from others' mistakes can make compliance easier and more effective.
Maintaining Nadcap accreditation remains crucial for quality systems in the aerospace industry. Understanding the common issues others face can help suppliers avoid similar pitfalls. This article examines the top findings from the Nadcap/PRI Heat Treat commodity, offering insights on how to stay compliant and avoid becoming part of the statistics.
AC7102 Checklist
PRI publishes the top findings on the eaudit.net site annually, accessible to those with log-in credentials. The list is divided into three categories: AC7102 (excluding job audits), AC7102 (including job audits), and AC7102/8. This article combines findings from all categories for a comprehensive overview.
Finding #1: AC7102 Para 1.1.4
The top finding relates to AC7102 Para 1.1.4, which requires suppliers to provide a completed self-audit, including all ten applicable job audits, to the auditor at least 30 days before the audit. This ensures that the entire checklist and necessary job audits are thoroughly addressed, demonstrating the supplier's compliance with Nadcap standards.
Suppliers often fall short by not completing the entire checklist or failing to include all ten job audits. This is especially challenging for initial audits, where simulated jobs using scrap material are necessary. To avoid this finding, suppliers should integrate the requirement for ten job audits into their internal audit procedures, use controlled templates for documentation, and set internal deadlines well ahead of the 30-day requirement. This preparation helps identify and rectify issues early, ensuring a smoother audit process and demonstrating robust compliance.
Finding #2: AC7102 Para 1.1.3
The second most common finding pertains to AC7102 Para 1.1.3, which mandates that suppliers provide specific documents to the auditor 30 days prior to the audit. These documents include a list of equipment, purchased services, prime customers, heat treat specifications, internal procedures for heat treating and pyrometry, and an organization chart.
Suppliers often miss one or more of these required documents, leading to findings. To avoid this, it’s crucial to create a controlled template that consolidates all necessary information. Regularly updating this template ensures accuracy and completeness. Additionally, setting internal submission deadlines well in advance of the 30-day requirement can help identify and address any missing documents, ensuring full compliance and a smoother audit process.
Finding #3: AC7102 Para 3.2.1.1
This finding involves AC7102 Para 3.2.1.1, which requires that all quality and technical requirements, including unique customer requirements, be adequately defined and documented. This ensures that every aspect of the heat-treating process meets specified standards and customer needs.
Suppliers often fail to capture and document specific customer requirements, leading to non-compliance. To address this, a thorough contract review process should be implemented to capture all requirements. Additionally, quality control should review work instructions to ensure all requirements are documented and properly flowed down to operators. Regular internal audits can help verify that all documentation is accurate and up-to-date.
Finding #4: AC7102 Para 3.4.1
The fourth common finding relates to AC7102 Para 3.4.1, which checks if all corrective actions from the previous Nadcap audit are still implemented. Ensuring the maintenance and effectiveness of these corrective actions is crucial for ongoing compliance.
Suppliers sometimes fail to maintain previous corrective actions, leading to repeated findings. This often occurs due to a lack of continuous monitoring and involvement from the quality team. To prevent this, the quality team should be actively involved in the internal audit process to ensure previous findings are properly closed and maintained. Implementing regular reviews and updates of corrective actions can help maintain compliance and avoid major findings in subsequent audits.
Finding #5: AC7102 Para 1.1.1.2
The fifth finding relates to AC7102 Para 1.1.1.2, which requires suppliers to identify and document the means of compliance for each checklist question. This includes providing references to procedures, forms, logs, or physical locations of evidence.
Suppliers often fail to adequately document where compliance evidence can be found, leading to audit findings. To address this, it is essential to ensure that each checklist question is accompanied by a detailed statement or reference showing how compliance is achieved. During internal audits, verify that all questions, even those deemed not applicable, have a clear and precise reference to the relevant procedures or documents. This thorough documentation helps demonstrate compliance and reduces the risk of findings.
Finding #6: AC7102 Para 7.2.2
This finding pertains to AC7102 Para 7.2.2, which mandates that all qualification, periodic, and lot/batch acceptance testing be conducted as required by specifications. This includes maintaining accurate records of all tests performed.
Suppliers sometimes fail to document all required periodic tests, their frequencies, and the specifications from which they are derived. To prevent this, suppliers should list all required periodic tests, along with their frequencies and corresponding specifications, in a centralized system. Using tools like Gauge-Track can help manage reminders and ensure timely execution of these tests. Regularly reviewing and updating test records can ensure compliance and readiness for audits.
Finding #7: AC7102 Para 9.1.2.1
The seventh finding involves AC7102 Para 9.1.2.1, which requires suppliers to have internal procedures that specify methods for determining heat-up rates, start and end of soaking times, and cooling rates. These methods must be clearly documented and followed.
Suppliers often overlook the need to document detailed methods for these critical parameters, leading to findings. To address this, suppliers should ensure that internal procedures include explicit instructions for determining heat-up rates, start and end of soaking times, and cooling rates. These procedures should be included in general heat-treating protocols and detailed in specific work instructions or routers when more precise or modified requirements are needed. Regular training and audits can help ensure adherence to these documented methods.
AC7102/8 Checklist
Below I will examine the findings in pyrometry, although it will relate to AMS2750E. Regardless of the revision, it is still worth recognizing and discussing the findings as it is still relevant.
Finding #1: AC7102/8 Para 4.2.4
The first finding in the AC7102/8 checklist relates to Para 4.2.4, which requires that instrument calibration records and stickers show conformance to AMS 2750E requirements or more stringent customer requirements. This includes identifying the instrument or furnace number on calibration stickers.
A common issue is the failure to update calibration stickers and records to reflect the specific requirements of AMS 2750E, such as including the instrument or furnace number. To address this, suppliers should ensure that their metrology departments are aware of and adhere to AMS 2750E requirements. This may involve updating calibration procedures and stickers to include all necessary details. Regular audits of calibration records and stickers can help ensure ongoing compliance and prevent findings.
Finding #2: AC7102/8 Para 4.1.2
This finding involves AC7102/8 Para 4.1.2, which mandates that the calibration of primary, secondary standard, and field test instruments meet the requirements of AMS 2750E or more stringent customer requirements. This includes specific calibration points and accuracy standards.
Suppliers often fail to calibrate field test instruments at the required six points across their range, or they do not meet the required accuracy standards of ±1.0°F or 0.1%. To ensure compliance, suppliers should review and update their calibration procedures to meet these requirements. Calibration certificates should be thoroughly reviewed to verify that all points and accuracy standards are met. Using secondary standard instruments for field calibrations can help maintain accuracy and compliance.
Finding #3: AC7102/8 Para 2.1.1
The third finding relates to AC7102/8 Para 2.1.1, which requires suppliers to have internal procedures addressing all aspects of AMS 2750E and any additional customer specifications. This ensures comprehensive coverage of pyrometry requirements.
A common issue is incomplete or outdated internal procedures that do not cover all required aspects of AMS 2750E. If any question on the checklist is marked "NO," this overarching question will also be marked "NO." To avoid this, suppliers should conduct a thorough review and update of their pyrometry procedures to ensure all aspects of AMS 2750E are addressed. Regular training and internal audits can help ensure these procedures are correctly implemented and maintained, thereby improving compliance and audit outcomes.
Finding #4: AC7102/8 Para 5.4.1
The fourth finding relates to AC7102/8 Para 5.4.1, which requires that the displayed temperature indication and recording of the sensor being tested, with appropriate offsets or correction factors, be compared with the corrected temperature indication of the test sensor on a test instrument at any operating temperature.
Suppliers often fail to apply or document the appropriate correction factors for control thermocouples and instruments, leading to inaccurate temperature readings. To avoid this finding, suppliers should ensure that all correction factors are applied and documented correctly. This includes updating procedures to require the use of correction factors in production and verifying their application during internal audits. Ensuring that test instruments are calibrated accurately and that all necessary corrections are applied will help maintain compliance.
Finding #5: AC7102/8 Para 6.1.1
This finding involves AC7102/8 Para 6.1.1, which mandates that internal TUS (Temperature Uniformity Survey) procedures conform to the requirements of AMS 2750E or more stringent customer requirements for the specific method used by the supplier.
Suppliers sometimes fail to ensure that their TUS procedures fully comply with AMS 2750E requirements, leading to non-compliance findings. Any finding associated with TUSs results in this question being marked "NO." To prevent this, suppliers should thoroughly review and update their TUS procedures to ensure they meet all AMS 2750E requirements. Regular training and internal audits focused on TUS compliance can help ensure that procedures are followed correctly and maintained.
Findings #6 and #7: AC7102/8 Para 6.7.1.d and Para 6.5.4
Finding #6 relates to AC7102/8 Para 6.7.1.d, which requires documentation of the performed TUS to include time and temperature data from all recorded sensors required for furnace instrumentation type for all zones tested. Finding #7 involves AC7102/8 Para 6.5.4, which mandates that temperatures indicated by all furnace thermocouples be recorded and included as part of the TUS record.
Suppliers often fail to include all required temperature data in the TUS documentation, leading to findings. To address this, suppliers should ensure that all TUS records include comprehensive time and temperature data from all sensors. This can be achieved by maintaining a complete TUS package that includes furnace charts and detailed temperature recordings. Keeping all relevant documentation together ensures that Nadcap auditors can easily review and verify compliance.
Finding #8: AC7102/8 Para 5.3.2
The eighth finding pertains to AC7102/8 Para 5.3.2, which requires that System Accuracy Tests (SATs) be performed upon installation and periodically thereafter in accordance with AMS 2750E Tables 6 or 7, or more stringent customer requirements, including any applicable frequency reductions.
Suppliers often struggle with understanding and implementing the extended frequency requirements for SATs, leading to non-compliance. To prevent this, suppliers should thoroughly understand the requirements for SAT frequency extensions and ensure that all necessary tasks are completed to qualify for extended intervals. This includes maintaining accurate records of SATs and ensuring all tests meet the specified standards. Regular training and audits can help ensure ongoing compliance with SAT requirements.
Avoid Common Issues
This overview of the top Nadcap heat treat findings highlights the importance of thorough preparation and adherence to requirements. By learning from these common issues, suppliers can enhance their compliance efforts and maintain robust quality systems. For detailed guidance and clarification, contact us at Conrad Kacsik directly.
