unconfirmed minutes€¦ · web view16-20 october 2006. omni william penn hotel. pittsburgh, pa....

COMPOSITES TASK GROUPOCTOBER 2006

UNCONFIRMED MINUTES16-20 OCTOBER 2006

OMNI WILLIAM PENN HOTELPITTSBURGH, PA

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, 16 OCTOBER 2006 (OPEN SESSION)

2.0 OPENING COMMENTS

2.1 Call to Order/Quorum Check

The Composites Task Group Meeting was called to order by David Watson at 1 p.m. A quorum of qualifying members was established; 13 prime voting members present

2.2 Introductions

The following representatives were in attendance:

User Members PresentName CompanyFrancis Averous ZodiacMike Bemis Goodrich AerostructuresJames Bratton Lockheed Martin - NMCSharon Bull Rolls Royce plcJerry Colombo Spirit AerosystemsLucia Cutillo Alenia Aeronautica s.p.a.Kevin Dowling Spirit AerosystemsJoe Dwyer Rolls-Royce Corp.Kevin Elston Vought AircraftOlivier Goupillon EurocopterBrett Hemingway BAE Systems (Air Systems)Mark Jackson Vought AircraftJamar Johnson Bell HelicopterJohn Key Bell Helicopter TextronBetty Kocsis Honeywell AerospaceEric Le Fort SONACA - BelgiumFrank Lennert The Boeing CompanyLance Loeks The Boeing CompanyAndreas Mastorakis GE AviationKeith Panuska Lockheed MartinDoug Prenovost Northrop GrummanGreg Sayler MD Helicopter

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Arun Sibal Lockheed MartinAllen Thiel General DynamicsDavid Watson Bombardier Inc.Larry Wilson Lockheed MartinSteve Wishnowski Bombardier Inc.

Other Participants/Members PresentIlhan Bayram Turkish Aerospace IndustriesPaul Braun CTLJohn Brunet OCM Test LabEd Budy Texas CompositesHassan Dabiri Ducommun AerostructuresJonathan Durocher Magellan AerospaceGekhon Erten Turkish Aerospace IndustriesErcun Evrensel Turkish Aerospace IndustriesJim Ferrel HexcelSean Finnerty Irish CompositesBrian Gallagher Henkel Corp, Aerospace GroupFabio Gasparotto Boeing – Hawker de HavillandMiguel A. Gerdel Thermal StructuresNiko Gjaja The M&P LabDave Gowryluk Magellan AerospaceEd Green C&D ZodiacClaveria Gregoire Marquez TranstechHiroki Hashitsume Mitsubishi Heavy IndustriesAlwin Heil Euro-CompositesThomas Hurst Hexcel CorporationBrian L. Johnson Royal Plastic Manufacturing Inc.David Kimber ATK Space SystemsCharles Lee AIDCJune Mason Texas Composites Inc.Issei Matsumoto MHI-NASWSkip McDougall Hitco CompositesJeff Mentel C&D ZodiacHitoshi Nada Mitsubishi Heavy IndustriesBill Newton Aircraft X-ray LabsJim Newton Aircraft X-ray LabsJeff Picasso AASCDavid Ponder Triumph GroupJohn Riddell St. Bernard Composites LTDDon Russel Toray CompositesJim Rossi Westmoreland TestingDavid Scott Hitco Carbon CompositesAndrew Sinclair Bodycote Testing GroupLouis Tseng AIDCDennis Walmsley Brookhouse Composites LtdFritz Watson Applied AerospaceDaniel Wienecke The Nordam GroupTimothy Willyard The Nordam Group

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Debra Wilsco Toray Composites

PRI Staff PresentRebekah Foutz PRI Staff (Warrendale, PA)

New Voting Members:Paul Braun Cincinnati Test Labs SVMKévin Elston Vought Aircraft Industries, Inc. AUVMSteve Grunsha

wBAE Systems – Air Systems AUVM

Thomas Hurst Hexcel ASVMKeith Panuska Lockheed Martin AUVMAllen Thiel General Dynamics Armament and

TechnologySVM

Jamar Johnson Bell Helicopter AUVMGregory C.

Sayler MD Helicopters UVM

2.3 Routing of Attendance List

The attendance list was routed for signatures.

2.4 Approval of Previous Meeting Minutes

The minutes from the 17-21 JULY 2006 Composites Task Group Meeting were reviewed. A motion was made for approval of the minutes, seconded, and all were in favor with no disapprovals. Therefore, the minutes were approved as written. All meeting minutes will be available on the PRI web site at www.pri-network.org.

2.5 Review of Agenda

2.5.1 The Staff Engineer (Rebekah Foutz) reviewed the agenda for the Composites Task Group October 2006 Nadcap meeting in Pittsburgh, PA with the task group members present.

3.0 STAFF/AUDITOR REPORT

3.1 Specific items of interest to Composites Task Group included:

3.1.1 AC7118 Rev A was released on 9 October 2006 and will be effective 8 January 2007. A mass email was sent to all Suppliers registered in eAuditNet informing them of the release and the impact it may have on already scheduled audits.

3.1.2 2006 Audit Projections

107 Projected

97 scheduled/conducted

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3.1.3 Presented the top ten NCR’s

An updated NCR Pareto chart was presented which detailed the most recurring findings to date for Composites audits conducted. The section in which finding was the most prevalent was “Do the design requirements and revision meet P.0 requirements”. This was the checklist question that had the highest number of findings overall. When comparing initial and reaccred audits, material storage findings have not shown an improvement between initial and reaccred audits; all other top ten NCR’s show improvement for reaccred audits. This presentation, including the specific questions, can be viewed on www.eauditnet.com under Public Documents – Composites.

3.2 Auditor Base Status

3.2.1 The current auditor base status were presented to the Task Group, currently have 4 auditors and 3 auditor trainees.

4.0 AUDITOR TRAINING REPORT OUT

4.1 Composite specific Auditor Training was conducted 15 October 2006. All but one auditor participated in the training. Steve Keck , Composites Lead Auditor, conducted training on Opening and Closing meetings and also provided some tips for conducting an audit. Task Group members presented information on the AC7118 Rev A, focusing on the major additions of a fourth scope of Liquid Resin Processing and job audits for Captive Laboratories.

5.0 METRICS

PRI presented the following charts regarding Composites Task Group metrics

Year to date audits chart Certifications issued chart First Pass Yield chart Number of cycles to close chart - initial audits Number of cycles to close chart - reaccred audits Total supplier cycle time chart - initial audits Total supplier cycle time chart - reaccred audits Staff engineer cycle time chart – initial audits Staff engineer cycle time chart – reaccred audits Task group cycle time chart – initial audits Task group cycle time chart – initial audits Suppliers on merit chart Prime audit balloting participation chart

Action Item- Investigate potential to break first pass yield into rolling 12 month yields rolled up quarterly – Rebekah (Due Date: 1/07 meeting)

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6.0 SUPPLIER SUPPORT COMMITTEE REPORT (MIGUEL GERDEL)

The Nadcap Supplier Support Committee (SSC) update was presented, including the mission and purpose of this committee. Current projects include: Supplier communication and mentoring team, supplier metrics, 2007 supplier survey, and 25 mile rule team. The minutes from the SSC meeting conducted on Tuesday, 16 October 2006 will be available on www.pri-network.org.

7.0 ACTION ITEM LIST REPORT OUT

The action items from the previous meetings were reviewed during the meeting as follows:

April 06 Action Item #3 and #8 are Closed

July 06 Action Items #1-10 and #12-14 are Closed

July 06 Action Item #11 remains Open

Action items are posted on eAuditNet under Public Documents - Composites.

Action Item- Clarify definition of EMA – Joe Dyer [lead,] & Brian Johnson (Due Date: 1/07 meeting)

Action Item- Clarify the use of irons – Sharon Bull [lead], John Riddell, & June Mason (Due Date: 1/07 meeting)

Action Item- Rebekah to have auditors to keep a list of the questions in checklist where yes is checked and N/A is the recorded response – Rebekah (Due Date: 1/07 meeting)

Action Item- Rebekah to provide Miguel Gerdel with statistics on the correlation of high number of audit findings and suppliers that participate or don’t participate in quarterly meetings (Supplier names will not be disclosed) – Rebekah (Due Date: 01/12/07)

TUESDAY, 17 OCTOBER 2006 (CLOSED SESSION)

CLOSED MEETING

A Closed meeting was held with only Primes attending. The topic discussed during the meeting was Staff Engineer delegation. A proposal was made to delegate Composites Reaccreditation audits only to Rebekah Foutz, Composites Staff Engineer, and was accepted with greater than a 2/3rds majority vote among Prime Voting Members.

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TUESDAY, 17 OCTOBER 2006 (OPEN SESSION)

7.0 ACTION ITEM LIST REPORT OUT CONTINUED

The action items from the previous meetings continued to be reviewed.

Action Item- Rebekah to compare with the NO- 008 and remove duplicate references in section 9.1.1 of NTGOP Appendix 14 – Rebekah (Due Date: 1/07 meeting)

Action Item- Rebekah to add incomplete audit to the follow-up audit criteria – Rebekah (Due Date 1/07 meeting)

Action Item- Rebekah to research Para 8.1 merit criteria and report back to task group – Rebekah (Due Date 1/07 meeting)

8.0 OPEN DISCUSSION - WAYS TO CUT COSTS AND/OR ADD VALUE

The Task Group was asked to consider topics related to the Composites Task Group and determine ways to cut cost or add value. All suggestions will be discussed at the January Nadcap meeting.

9.0 RESOLUTION OF AUDITOR HANDBOOK COMMENTS

The comments from the ballot of the AC7118 Auditor Handbook were discussed and resolved by the task group members in attendance.

Action Item- Create cover page for auditor handbook– Rebekah (Due Date: 11/01/06)

Action Item- Define acceptable vs unacceptable types of portable dehumidifiers –Francis Averous (Due Date: 11/01/06)

Action Item- Review Auditor Handbook Section 10 and verify where the general statements should be located in the sub sections – Andreas Mastorakis (Due Date: completed)

10.0 OPEN DISCUSSION – NEW BUSINESS

10.1 John Riddle requested discussion regarding clarification of if and where pneumatic presses might be permitted in the clean room.

10.2 June Mason requested discussion regarding clarification of material out time recording.

10.3 Discussed Istanbul meeting attendance commitment

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WEDN ESDAY, 18 OCTOBER 2006 (OPEN SESSION)

9.0 RESOLUTION OF AUDITOR HANDBOOK COMMENTS (CONTINUED)

Discussion of handbook comments and their resolution was continued from Tuesday’s meeting. A proposal was made to release the handbook with current resolved comments to support upcoming audits. Motion was made to accept the proposal, seconded and voted. Proposal was accepted by 2/3 majority vote. The resolutions agreed to are recorded in the attached comments table.

Action Item- Revise Auditor Handbook to put generic text in the general section for material identification and to add specific text where it applies to an individual material type including core protection requirements – John Key, Dave Kimber & Miguel Gerdel (Due Date: 1/07 meeting )

Action Item- Meet with Jen Gallagher to get specifics regarding NCSI session – Rebekah (Due Date: 11/01/06 )

Action Item- Release Auditor Handbook Rev A-1 – Rebekah (Due Date: 11/01/06)

11.0 NEXT MEETING DATE AND LOCATION

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

The Composites Task Group will tentatively meet on Monday, 22 January through Wednesday, 24 January 2007. The Non Metallic Materials Testing Sub-Group will tentatively meet on Thursday, 25 January through Friday, 26 January 2007.

The formal agenda will be developed, distributed and will be available on www.pri-network.org. Topics will include addition of clarification to the Auditor Handbook, Redundant Audits and Material Specification and Revision and Configuration Control.

WEDN ESDAY, 18 JULY 2006 (CLOSED SESSION)

CLOSED SESSION

A Closed meeting was held with only Primes attending. Topics of discussion included Auditor interviews, Auditor consistency, approval of new Supplier

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Voting Members, Staff Engineer requirements to be a Composites Auditor, discussion of audits in Task Group Review, and Prime and Supplier participation in Task Group meetings.

Action Item- Request the NMC for a matrix to track the ratio of major and minor among task groups. – David Watson (Due Date: 11/1/06 )

ADJOURNMENT – The meeting was adjourned at 4 p.m.

THURSDAY , 19 OCTOBER 2006 (OPEN SESSION)

Non-Metallic Materials Testing Sub Group

1.0 PILOT AUDIT DISCUSSION

The first AC7122 pilot audit was completed on 3-6 October 2006 at a raw material manufacturer. Prime support was provided by GE Aviation, Honeywell Aerospace, Lockheed Martin and Goodrich Aeostructures Group. Three (3) additional Suppliers have volunteered to participate in a pilot audit. Estimate that the next pilot audit will take place in February 2007, testing the checklist at an independent lab.

ACTION ITEM: Bekah to check with Paul McCarthy to determine training needs so that he can participate in the next pilot audit.

11.0 RESOLUTION OF BALLOT AND PILOT AUDIT COMMENTS

The comments from the ballot of the AC7122 and the pilot audit were discussed and resolved by the task group members in attendance. Betty Kocsis will be incorporating all changes to the AC7122/1, Mike Bemis will be incorporating all changed to the AC7122/2, and Andreas Mastorakis will be incorporating all changes to the AC7122. The resolutions agreed to are recorded in the attached comments tables.

ACTION ITEM: Arun Sibal to check correlation with new ASTM procedure being developed for DMA 3-point flex, Para 7.4.3.

ACTION ITEM: Mike Bemis to restructure DSC section to add SACMA SRM 25 requirements, Andy Sinclair will critique

ACTION ITEM: Jim Rossi to get ISO class identification from Uta Dietrich for Para. 3.2.4

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ACTION ITEM: Andreas Mastorakis to contact Uta Dietrich regarding appropriateness of using ASTM D746 for Determination of Brittleness Temperature for composites

ACTION ITEM: John Key (will talk to Cessna), Uta Dietrich, Lance Loeks and Frank Lennert to review tests 5.3.1 – 5.9.1 (flammability, toxicity, etc.) to determine applicability to AC7122

ACTION ITEM: Lance Loeks to fix 5.1.12.4 (i.e. What is periodic?)

ACTION ITEM: Betty, Frank and Niko to clarify Para. 23 and 24 regarding test reports vs certifications. Combine?

12.0 AUDITOR HANDBOOK DEVELOPMENT

The AC7122/1 and AC7122/2 were broken up into sections and specific members of the Task Group were assigned paragraphs to create Auditor Handbook clarification.

ACTION ITEM: Niko Gjaja, Frank Lennert (lead), Brian Gallagher, Brian Johnson, and Miguel Gerdel to create Auditor Handbook clarification for paragraphs 23-26 of the AC7122/1

ACTION ITEM: Brett Hemingway (lead) and Paul Braun to create Auditor Handbook clarification for all job audits related to Mechanical tests

ACTION ITEM: Jim Ferrel (lead) and Don Russell to create Auditor Handbook clarification for all job audits related to Physical Tests

ACTION ITEM: Joe Dwyer (lead), Andrew Sinclair and Olivier Goupillon to create Auditor Handbook clarification for all job audits related to Thermal Tests

ACTION ITEM: Uta Dietrich and Lance Loeks to create Auditor Handbook clarification for all job audits related to Fire Tests

FRIDAY, 20 OCTOBER 2006 (OPEN SESSION)

13.0 ACTION ITEM REPORT OUT

The action items from the previous meetings were reviewed during the meeting as follows:

July 06 Action Items #1-25, 27 and 28 are Closed

July 06 Action Item #26 remains Open

Action items are posted on eAuditNet under Public Documents - Composites.

ACTION ITEM: Mike Bemis to delete question regarding low CTE of TMA expansion probe in AC7122/2

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ACTION ITEM: Rebekah Foutz to send Daniel Ng (Hexcel) e-mail regarding pilot audit

ACTION ITEM: Rebekah Foutz to provide Paul Braun with details on audit costs and possible dates

14.0 INTER LABORATORY TESTING (ROUND ROBIN TESTING)

Proposed parameters were determined for first ILT as follows

14.1 Ambient Tensile14.1.1 ASTM D3039 14.1.2 Carbon fiber specimens to be provided by Toray14.1.3 Modulus required by strain gage

14.2 Ambient Compression14.2.1 ASTM D695 modified per SACMA SRM 3R9414.2.2 Tabbed compression specimens to be provided by Toray14.2.3 No modulus required

14.3 Tg by TMA 14.3.1 ASTM D154514.3.2 Specimens provided by Toray14.3.3 Match parameters used by Toray for internal testing

ACTION ITEM: Rebekah Foutz to send e-mail to all suppliers asking who will participate in ILT (Inter Laboratory Testing, often referred to as Round Robin)

FRIDAY, 20 OCTOBER 2006 (CLOSED SESSION)

CLOSED MEETING

A Closed meeting was held with only Primes attending. Topics of discussion included pilot audit results, auditor training, and future pilot audit plans.

15.0 NEXT MEETING DATE AND LOCATION

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

The Composites Task Group will tentatively meet on Monday, 22 January through Wednesday, 24 January 2007. The Non Metallic Materials Testing Sub-Group will tentatively meet on Thursday, 25 January through Friday, 26 January 2007.

The formal agenda will be developed, distributed and will be available on www.pri-network.org. Topics will include addition of clarification to the Auditor Handbook, Redundant Audits and Material Specification and Revision and Configuration Control.

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ADJOURNMENT – The meeting was adjourned at 4 p.m.

Minutes Prepared By:Rebekah Foutz [email protected] Bemis [email protected] Kocsis [email protected]

ACTION ITEM LIST

***** 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 revision:

Who is responsible: Due date:

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mailto:[email protected]

