Coatings Task Group

Audit Handbook

Release:
November 2011

PERFORMANCE REVIEW INSTITUTE

161 THORNHILL ROAD
WARRENDALE, PA 15086-7527
+1 724 772 1616
Nadcap November-2011
Coatings Task Group
Audit Handbook

TABLE OF CONTENTS

FOREWORD ................................................................................................................... 1 

1.0 GENERAL .............................................................................................................. 1 

2.0 GUIDELINES FOR TIME MANAGEMENT OF THE AUDIT .................................. 6 

3.0 AUDITING AIDS .................................................................................................... 6 

4.0 AUDITING TO COATINGS AUDIT CRITERIA ...................................................... 7 

AUDITING TO AC7109 AUDIT CRITERIA ................................................................. 7 

AUDITING TO AC7109/1 THERMAL SPRAY ............................................................ 7 

AUDITING TO AC7109/2 VAPOR DEPOSITED COATINGS ................................... 10 

AUDITING TO AC7109/3 DIFFUSION COATING PROCESSES ............................. 11 

AUDITING TO AC7109/4 STRIPPING OF COATED MATERIAL............................. 12 

AUDITING TO AC7109/5 COATING EVALUATIONS (SHOP FLOOR AND

LABORATORY) ........................................................................................................ 14 

AUDITING TO AC7109/6 PLATING OF COATED PARTS ...................................... 14 

AUDITING TO AC7109/7 HEAT TREATING FOR SUPPLIERS OF COATINGS ..... 15 

APPENDIX 1 – OPENING MEETING CHECKLIST ...................................................... 17 

i
Nadcap November-2011
Coatings Task Group
Audit Handbook

FOREWARD

This Handbook has been prepared to assist the Coatings Auditor and Supplier as follows:

a) Where necessary, provide clarification on the intent and rationale of the Task Group as it
pertains to specific questions contained in AC7109 and associated “Slash Sheets.”

b) Clarify the material to be reviewed in addressing audit questions.

c) Standardize the audit from auditor to auditor.

d) Provide general guidance on Task Group expectations on conducting the audit.

e) Provide general information on unique requirements of participating Subscriber

contractors to aid the auditor in determining supplier conformance to customer
requirements.

f) Assist the supplier throughout the audit process.

g) Standardize objective evidence expectations.

1.0 GENERAL

1.1 AUDITING GUIDELINES

Coating Auditors shall comply with the general requirements for completion of the
checklist contained in the core Nadcap Auditor Handbook. These requirements include,
but are not limited to:

1.1.1 All NO Answers should be supported by an NCR. If “No” is an acceptable answer to a

question and no NCR is required, then a short statement of explanation shall be
included.

1.1.2 All questions must be addressed – Do not leave sections blank and assume that the
Task Group will understand why it is blank.

1.1.3 All N/A’s shall be explained with supporting remarks.

1.1.4 All descriptive sections shall be completed, except as directed in the checklists.

1.1.5 “Combine Findings” – When practical, the auditor may combine findings that are closely
related on one NCR.

1.1.6 For each NCR the auditor must indicate in the assessment section whether or not there
is adverse product impact from the finding.

1.2 All findings from previous audit must be reviewed and verified during the course of the
coatings audit. A condition for extended frequency audits is the absence of repetitive
NCR’s.

1
Nadcap November-2011
Coatings Task Group
Audit Handbook

1.3 If a product impact issue is discovered during the audit, notify PRI Staff Engineer
immediately by telephone.

1.4 In addition to the general auditor requirements for completion of the checklist, Coatings
Auditor shall comply with the following:

1.4.1 Abbreviations shall not be used.

1.4.2 The use of acronyms shall be limited to commonly accepted and understood acronyms
(i.e., FAA, DoD, HVOF, LPPS, etc.)

1.5 Can auditors close out findings on site? Answer: No, Auditors cannot close a finding.
Corrective Actions may be accepted on site by the Auditor but make sure that the
supplier understands that the Staff Engineer or Task Group may re-open the finding as
deemed necessary. The record of the NCR and corrective action must still be reported to
the task group. Reference NIP 7-02 5.6.

1.6 The coatings task group has adopted the definitions of Major and Minor findings as
contained in PRI Quality Manual. Each finding shall be categorized.

1.7 Auditors shall preferentially perform job audits of participating Subscribers fully
approved, OEM production parts. When available, subsequent audits should address
different parts and different Subscribers.

1.7.1 Auditors shall complete The Job Audit and Test Method Tracker to ensure that all
processes, specifications, and primes in the scope of the audit are reviewed during job
audits over a period of time. The auditor is to review the Tracker prior to the audit and
communicate with the supplier requesting hardware be made available (to the extent
possible) for processes, primes and specifications that have not been reviewed in
previous audits. 1.7.2 When performing audits and documenting findings, be sure to
identify affected P/N, Specification number, Paragraph number, and Job number.

1.7.3 In case the auditor needs to find out what is the current specification/drawing level or a
Subscriber specification interpretation, he may call the Subscriber contact, with the
supplier (on the phone at the same time):

Company Name Contact Telephone Email

Eurocopter (EADS) Nicolas Barthelemy nicolas.barthelemy@eurocopter.com

GE Aviation John Nerz +1 513 243 5112 john.nerz@ae.ge.com

Goodrich Corporation Ben Evans ben.evans@goodrich.com

Honeywell Aerospace Jack Saunders +1 602 231 1189 jack.saunders@honeywell.com

Parker Aerospace Group Dan Loveless dloveless@parker.com

Rolls-Royce Corp. Tim Pruitt +1 317 230 3728 timothy.j.pruitt@rolls-royce.com

Rolls-Royce, plc Jon Higgins jon.higgins@rolls-royce.com

SAFRAN Group Fabrice Crabos fabrice.crabos@turbomeca.fr

(Turbomeca)

2
Nadcap November-2011
Coatings Task Group
Audit Handbook

Triumph Group, Inc. Robert Nixon +1 972 946 0895 robert_nixon@voughtaircraft.com

UTC (PWA, PWC, Clark Okawa clark.okawa@pw.utc.com

Hamilton Sundstrand,
Sikorsky)
Volvo Aero Corp Jan Wigren jan.wigren@volvo.com

1.7.4 Accept findings on site: Minor (and only minor) non systemic findings may be accepted
on site. The Supplier must address the finding to the auditor’s satisfaction and show the
changes, including training records if necessary. If the finding is accepted, clearly
describe the actions that were taken by the supplier to address the finding. This is
necessary to ensure that no more information is needed from the supplier to close the
finding. Make sure that the supplier understands that the finding is only accepted. It can
only be closed by the Task Group or the Staff Engineer and may be re-opened, although
this is not the intention.

It is important for the auditor to understand that the ability to accept findings on site is
available and encouraged when appropriate. We understand that there are times when a
supplier trying to fix everything on site is distracting to effective completion of the audit.
This must be dealt with and you may contact the Staff Engineer for assistance with this if
needed. However, there are times when an effective solution can be developed and
completed while the auditor is on site. We do not want to lose track of this.

1.8 If additional time (day) is needed during an audit due to: additional audit scope,
unusually large number of findings or investigation into product impact issues, contact
the staff engineer or scheduling immediately for approval first.

1.9 If the audit is finished early by a full day or more, the staff engineer and/or scheduling
must be contacted for approval prior to leaving the facility.

1.10 During the debriefing meeting at the end of the audit, please advise the Point of Contact
of typical objective evidence required to close findings.

#1 If a procedure change is made, you need to submit the approved revision,

controlled version of the revised copy along with the evidence of training the
appropriate personnel to the changes. Evidence of implementation is also typically
requested.

#2 If internal procedure was violated, you need well-defined root cause identifying why
this occurred. The Task Group needs to see the corrective action (such as training)
as well as evidence of implementation of oversight system to ensure procedures
are followed.

1.10.1 During the closing meeting, clearly explain each NCR.

1.10.2 During the debriefing meeting, please review the root cause evaluation requirements.
Proper/thorough evaluation of the root cause and implementation of effective corrective
actions to address the root cause issues is the key to successful response and closure
of findings. This will likely result in fewer requests for additional information/evidence.

3
Nadcap November-2011
Coatings Task Group
Audit Handbook

This will also increase the likelihood of being placed on the supplier merit program.
(Briefly discuss the merit program with the Point of Contact).

1.10.3 Also, during the debriefing meeting, discuss the responses to observations with the Point
of Contact. Responses are not required but it is in their best interest to respond. This can
help the Task Group/Staff Engineer to decide if this is a finding or not. Make sure the
Point of Contact knows that if he/she has any questions to contact the Coatings Staff
Engineer.

1.10.4 Ensure that the point of contact is aware of the criteria for number of rounds which can
lead to Task Group review for failure. Associated with this, advise the contact to not use
eAuditNet for simple questions or requests for clarification as they will increase the
number of rounds. These should be handled by a telephone call or an email to the Staff
Engineer.

1.10.5 Give the “Post-Audit Letter” to the Point of Contact.

1.11 Best practices for auditors are summarized below:

1.11.1 To make the audit effective:

a) Talk with the operator.

b) Review the operation sheet for flowdown.
c) Identify parts in process, copy traveler, secure specifications/prints/instructions,
query operators to ensure that they understand their job, explain the philosophy—
how well does the operator understand his/her job.
d) Discuss with the operators without external prompting of answers. However,
ensure that there is an additional supplier representative present.
e) Pick a job/PO and walk through the system and audit the elements as applicable.
f) Get the job, specs, and identify subtier specs, compare revision dates, rev. date of
process sheet vs. latest specification requirements. Identify mechanism to ensure
compliance. Ensure proper release authorization.
g) Witness a part in process. If available, walk/audit from beginning to end (receiving
to shipping), look at certifications, and have the operator explain why they
accepted this certification.
h.) Verify effectiveness of powder control system. These are often weak.

1.11.2 How to maintain good relations with supplier during an audit:

4
Nadcap November-2011
Coatings Task Group
Audit Handbook

DO’s/Best Practices Don’ts

Make the Supplier feel at ease Don’t dwell on findings

Make sure that you brief supplier with what Don’t divulge proprietary information
you’ve found
Maintain a non-adversarial relationship Don’t give off negative body language

Audit to requirements, not opinions Don’t threaten and celebrate NCRs

Be aware of cultural differences. Don’t lose temper no matter what happens

Explain referee and appeal methods before Don’t gloat or make jokes
the audit
Be prompt Don’t use inappropriate language

Be honest Don’t criticize the checklist or process

Contact PRI staff if you have questions Do not mix personal opinion with requirements

Be professional Don’t allow extended discussions on findings

Be respectful of supplier and circumstances Don’t write root causes as problems

Be open minded and let supplier provide Don’t tell dirty/inappropriate jokes. Don’t be
evidence and documentation crude.
Know what you’re talking about Don’t say how many findings that you’re going to
find during the upcoming audit.
Work together with supplier when writing an Don’t assume that you’ll have NCRs going into
NCR the facility
Explain audit methodology of what is coming Don’t sell consulting services during the audit.
(agenda) at In-Briefing
Admit when you make a mistake Don’t dictate corrective action.

Compliment the supplier on their systems

where appropriate

5
Nadcap November-2011
Coatings Task Group
Audit Handbook

2.0 GUIDELINES FOR TIME MANAGEMENT OF THE AUDIT

2.1 Manage your time spent in the various sections of the audit, systems – technical – job
audits, to allow for a timely completion and debriefing of Executive Management
personnel on the final day.
3.0 AUDITING AIDS

3.1 The Coatings Task Group has developed several aids to assist both auditors and
suppliers in auditing and understanding and interpreting checklist criteria. The first is this
audit handbook. The next sections provide specific interpretations for auditing to each
checklist.

3.1.1 Objective Evidence Checklists – The Task Group has identified what would be expected
to be seen for objective evidence for most checklist questions. These checklists can be
downloaded from eAuditNet in Public Documents. They can be used instead of the PRI
checklists when performing audits on paper checklists as they contain the same
questions as the PRI checklists. It is important to note that these evidence lists are not
exhaustive and there are other ways in which compliance with requirements may be
shown.

3.1.2 Subscriber Job Audit Guidelines – Each Subscriber has the opportunity to develop a
Subscriber job audit guideline. These are also found in eAuditNet in Public Documents.
The job audit guideline is the job audit section for each checklist and can be used as a
job audit checklist when performing a job audit for that Subscriber’s parts. The checklist
will include specific information to look for when reviewing a job for that Subscriber. It
may include where to look for information, additional information to look for or
clarifications. A more current specification revision than that defined in these guidelines
will override requirements defined in these guidelines. The developed guidelines must
meet the following criteria:

1. These guidelines only contain requirements which are currently requirements

of specific Subscribers.

2. Statements/Questions will be linked (and referenced) to job audit questions of

Nadcap checklists (except for AC7109/5).

3. Questions will have reference to Subscriber specification, including revision

level and paragraph number

4. Guidelines will only be used when performing a job audit of that Subscriber’s
hardware. If no job audit to that Subscriber, guidelines will not be used

5. Control of keeping current to Subscriber requirements is responsibility of

Subscriber sitting on the CT TG. If that Subscriber loses representation to the
Task Group, the guidelines will be removed.

3.2 For findings which violate customer engineering requirements (such as specification,
drawing or frozen process requirements), the response must contain evidence of
customer notification. This notification must include the following information:

6
Nadcap November-2011
Coatings Task Group
Audit Handbook

1) Description of violation/Details of engineering requirements

2) Who was contacted with title/function
3) Point of contact for processor (sender of letter typically)

Other information which is not required but would assist in resolving the issue more
quickly with the customer is:
1) Approximate time frame of violation
2) Listing of parts/all affected parts – Quantities, ship dates, status
3) Preliminary plan for corrective action

4.0 AUDITING TO COATINGS AUDIT CRITERIA

General Note for All Checklists: When parameters are automatically controlled, there does
not need to be a tolerance on the setting, but there does need to be a tolerance on the
parameter for monitoring of the process.

“e.g.” and “i.e.” are used to define possible examples and are not meant to be definite
requirements.

“etc.” means and others.

Frozen process can also be called a Fixed Process.

AUDITING TO AC7109 AUDIT CRITERIA

General guidance from the Task Group on auditing to AC7109 and specific interpretation to
questions.

5. TESTING AND GENERAL PROCESS INSPECTION AND TRAINING

5.2.3 Customer Requirements for retention of metallographic specimens

GE – Two (2) years

Honeywell – (TBD)
Pratt and Whitney – Ninety (90) days for conforming, One (1) year for non-
conforming
Rolls-Royce, plc – No requirement
Rolls-Royce Corp. – No requirement
Bombardier – No requirement

5.2.4 At this time, there are no approved equivalent laboratory accreditations.

5.3.1 The general requirement is that if the parameter is called out in the tech plan/frozen
process/operation sheet/work instructions, the instrument must be calibrated. Supply
gauges for which there are process control gauges further downstream which can be
adjusted do not need to be calibrated.

AUDITING TO AC7109/1 THERMAL SPRAY

7
Nadcap November-2011
Coatings Task Group
Audit Handbook

General guidance from the Task Group on auditing to AC7109/1 and specific interpretations to
questions.

DEFINITIONS

Articulations – Movement

Crazing – Network of cracks

Fixturing / Tooling / Hard Tooling – Items specifically designed to hold or fasten to components
during processing; tooling used to hold or mask components

Hardmasking – Masks, fixtures or tools made from rigid materials (metal, hard rubbers/plastics,
etc.) used to protect areas during grit blasting, or to prevent coating being deposited
where it is not required

Matte Finish – A surface that is dull or not reflective

Torch Configuration – Details of the Spray gun and variable components used to build it, e.g.
nozzle, powder injector

Work Instruction – Document describing how a particular operation is to be performed

4. MATERIAL POWDER/WIRE CONTROL

4.2.h Controlled conditions means:

Powder/Wire lot control

Designated powder/wire storage area
Release control – Method of logging in and out – maintain controlled inventory system.
Procedures that avoid mislabeling powder
Specific customer requirements
Receiving pending approval
Humidity and temperature not applicable

9. OXY/FUEL (SEE NOTES)

10. PLASMA THERMAL SPRAY (SEE NOTES)

11. HVOF/HVAF (SEE NOTES)

12. D-GUN SYSTEMS (SEE NOTES)

13. LOW PRESSURE PLASMA SYSTEMS (LPPS) (SEE NOTES)

14. ELECTRIC ARC WIRE (SEE NOTES)

8
Nadcap November-2011
Coatings Task Group
Audit Handbook

NOTE 1: If a job audit is not performed for a particular technology (oxy/fuel, LPPS, etc.),
procedures and/or process plans, etc. must be reviewed for these other technologies to
ensure requirements for process control.

NOTE 2: Subscriber Requirements related to Part temperature control.

GE Aviation Frequency must be defined in Quality Plan. Must be verified on

each lot unless data can substantiate reduced sampling.

Honeywell TBD

Rolls-Royce, plc and Corp. Temperature defined in specification. Validation first run
acceptable.

Pratt and Whitney Defined in specification or validated during first run.

Bombardier Defined in specification and validated in first run.

Auditor direction – Check:

1. Supplier has a procedure for part temperature measurement.

2. Operator complies with this procedure.
3. Object evidence of measurement in compliance with customer requirements
4. Frequency, method, and temperature comply with customer requirements

Some examples of part measurement techniques:

- Infrared gun (quantitative)

- Thermocouple on part (i.e. contact pyrometry) (quantitative)
- Temperature Sticks (qualitative) – provides a temperature exceeded
- Stickers (similar in function to Temperature Sticks) (qualitative) – provides a
temperature exceeded.

Part temperature control may be monitored during part qualification. If this is acceptable
per the spec, it is not a finding. There must, however, be evidence of this, such as a
FAIR. If it is unclear if this is acceptable, this should be written as a finding or the staff
engineer may be consulted. The staff engineer can follow up with the Subscriber to
determine if this is acceptable.

20. COMPLIANCE AUDIT

20.1.2b For GE Aviation, Revision Level on Farmout Instructions supersedes Revision Level
on Purchase Order when performing work directly for GE.

9
Nadcap November-2011
Coatings Task Group
Audit Handbook

AUDITING TO AC7109/2 VAPOR DEPOSITED COATINGS

General guidance from the Task Group on auditing to AC7109/2 and specific interpretations to
questions.

DEFINITIONS

Chamber – The vessel in which components are coated

Controlled Environment (for storage of materials) – Protected from conditions that may degrade
them, for example contamination, moisture, heat, cold

Documented – A physical or electronic record that provides information or evidence

Dwell (for grit blasting) – A pause in the motion of the grit stream relative to the component

Fixed Process / Frozen Process – A process that can only be changed with the approval of the
customer

Foreign Material/Contamination – Material that is not supposed to be there

Inspection Plan – Procedures and acceptance standards for inspection of coated components

Instructions (Operation Sheets, Work Instruction, Procedure, Shop Paper) – Document

describing how a particular operation is to be performed

Interface – The junction of the component base metal and the coating or between different
coating materials

Masking – The application of a barrier used to protect areas during grit blasting, or to prevent
coating being deposited where it is not required

Parameters – Factors or characteristics that are used to control a process

Part Substrate – The material of the component being coated

Reconditioning (of tooling) – Restoring tooling to the original dimensions and condition

Router/Shop Traveler – Document used to control the sequence of manufacturing operations

and identify batches of components

Specification – Document with detailed requirements for a process, material or component

Test Specimens – Material that may be examined for conformance to specification.

Tolerance Limits – Amount of variance from a target value that is permitted for a parameter;
may alternatively be expressed as a range of values, a minimum or a maximum

Ventilated (grit blast booths) – Air is extracted to prevent dust build-up

10
Nadcap November-2011
Coatings Task Group
Audit Handbook

11. PROCESS GASES

11.4 The first and desired option for monitoring dew points is to use a dew point meter to
measure the gas at the inlet to the chamber/reactor.

A second option for PVD processes only to monitor dew point on all but toxic gases has
four requirements that must be met in order to use it:
1) High purity gas (99.999% pure) must be used
2) Each bottle must have an individual certification of purity
3) There must be a dedicated gas line from one bottle to one reactor
4) There must be a helium leak detection check along the entire gas line, from
source to inlet, with a written procedure and documentation of results to occur
with after every line disruption (e.g. bottle change, hit with forklift, etc.).

This second option may only be used where there are no customer or Subscriber
requirements to physically measure the dew point. GE and PWA have stated that they
have requirements to measure the dew point and this option is not viable for work
performed for these Subscribers.

16. COMPLIANCE AUDIT

16.1.2b For GE Aviation, Revision Level on Farmout Instructions supersedes Revision Level
on Purchase Order when performing work directly for GE.

16.1.2f Technical plan is defined as the top level document describing the processing for a
part.

16.1.3.1 No is not an NCR.

AUDITING TO AC7109/3 DIFFUSION COATING PROCESSES

Guidance from the Task Group on auditing to AC7109/3 and specific interpretations to
questions.

DEFINITIONS

Controlled Environment – Protected from conditions that may degrade them, for example
contamination, moisture, heat, cold

Fixturing – Items specifically designed to hold or fasten to components during processing.

Tooling used to hold or mask components

Foreign Material/Contamination – Material that is not supposed to be there

Instructions (Operation Sheets, Work Instruction, Procedure, Shop Paper) – Document

describing how a particular operation is to be performed

Mechanical Cleaning – Grit blasting to clean parts

Nuggets/Rocks – Material in pellet form used as the source of the coating vapor; slugs.

11
Nadcap November-2011
Coatings Task Group
Audit Handbook

Parameters – Equipment settings and required conditions that are used to control a process

Part Orientation – How the part is positioned during coating

Part Substrate – The material of the component being coated

Procurement – Purchasing

Rejuvenation – Processing of the used coating source material so that it may be used again;
reconditioning

Reprocessing – Re-application of the coating, either as an additional layer, or following the

removal of the previous coating; may include coating removal

Retort/Box/Coating Pan – The container in which components are placed for coating; this may
then be placed within a larger container

Segregation (of material) – Identification and isolation of material separate from other materials

Supplemental Heat Treat – Heat treatment carried out after coating deposition

Thermal Cycle – The periods of time at various temperatures from start to finish of the process

Thermocouple (Control, Indicating, Load)

Control thermocouple – Thermocouple connected to the furnace temperature controller

Indicating thermocouple – Thermocouple connected to a recording instrument

measuring process equipment temperature

Load thermocouple – Thermocouple sensing component temperature, either attached to

a part or buried within the load

Ventilated (grit blast booths) – An air extraction system is used to remove dust from the blasting
booth

Activator – Chemicals used to generate the active species of the coating vapor

Pack/Pack Mix – Coating source material in powder form

Conditioning (of coating pans/fixtures) – Coating or stabilizing of new or repaired/renovated

vessels or tooling, before they are used for coating components

Slurry – Coating source material that is applied to the components as a solid suspended (not
dissolved) in a liquid

AUDITING TO AC7109/4 STRIPPING OF COATED MATERIAL

12
Nadcap November-2011
Coatings Task Group
Audit Handbook

General Guidance for the Task Group on auditing to AC7109/4 and specific interpretations to
questions.

DEFINITIONS

Arc detector, Auto shutdown mechanism – A mechanism to detect poor electrical connections
that are causing electrical discharges (arcing) and current spikes, and automatically cut
the power

Blast Media – Materials used in grit blast operations, e.g. alumina grit

Constituents – Ingredients, chemicals or components of a mixture

Embrittlement Relief Bake – Heat treatment to remove hydrogen from steel components

Entrapment (of air or liquids in components) – Air pockets that prevent the free access of
solutions to the component surface; or small amounts of liquid that cannot be removed
from a component

Frozen Parameters – Equipment settings and required conditions that are used to control a
process and may only be changed with the approval of the customer/Subscriber

Galvanic Coupling – Physical contact between metals with different electrochemical potential
resulting in an increased rate of attack or corrosion

Halted – Stopped

Identity of Individual – Name or identification of the operator

Inhibited – Addition of chemicals to reduce the rate of chemical attack on the substrate

Initial tank make-up – Preparation of a tank of new solution

Log – Records, documentation of results

Media Sources – Suppliers of materials used in mechanical stripping processes, e.g. blasting
grit

Precluded – Prohibited, not allowed

Process/Technical Plan – Top level document that describes all the processing of a component

Sample collection – Taking a sample

Serialized – Having a unique identification code

Stamped off – Recording that an operation has been completed

Strip Rate Determination – Control of stripping solution by measurement of the amount of

material stripped over time

13
Nadcap November-2011
Coatings Task Group
Audit Handbook

Tank Dump – Disposal of the solution in a tank

5. PROCESS CONTROL LABORATORY PROCEDURES

5.3.7d ARP4992 gives guidelines to follow for increase and decrease of analysis frequencies.

AUDITING TO AC7109/5 COATING EVALUATIONS (SHOP FLOOR AND

LABORATORY)

General Guidelines from Task Group on auditing AC7109/5 and specific interpretations to
questions.

DEFINITIONS

Impression – Indentation

LPPS – Low pressure plasma spraying

PVD – Physical vapor deposition

Stage Micrometer – Device with calibrated microscopic scale to calibrate microscope

magnification, image analysis software or any optical measuring device

Surface Finish – How rough a surface is

Witness test – Witnessed by auditor

9.3, 9.4, 9.5 A procedure is required. If there is not a procedure defining the required
elements, it will be written up as a finding. This is a common area for initial audit
findings.

9.3e Special fixtures are to be used when required. Does customer require special fixtures? If
not, then N/A.

AUDITING TO AC7109/6 PLATING OF COATED PARTS

General guidance from the Task Group on auditing to AC7109/6 and specific interpretations to
questions.

3. EQUIPMENT AND FACILITIES

3.19 Physical restart of the power after failure is to ensure that there is notice that the power
has failed and to protect parts from a surge when power returns.

14
Nadcap November-2011
Coatings Task Group
Audit Handbook

9. PROCESS CONTROL LABORATORY PROCEDURE (SOLUTION ANALYSIS)

9.7d ARP4992 gives guidelines to follow for increase and decrease of analysis frequencies.

AUDITING TO AC7109/7 HEAT TREATING FOR SUPPLIERS OF COATINGS

General guidance from the Task Group on auditing to AC7109/7 and specific interpretations to
questions.

DEFINITIONS

Thermocouple (Control, Indicating, Load)

Control thermocouple – Thermocouple connected to the furnace temperature controller

Indicating thermocouple – Thermocouple connected to a recording instrument

measuring process equipment temperature

Load thermocouple – Thermocouple sensing component temperature, either attached to

a part or buried within the load

7. PYROMETRY TESTING

7.1. Mostly, the uniformity requirements will be ±25ºF (±14ºC). Typically furnaces will be
Type A, Class 1.

7.5.2 2ºF = 1ºC, 50ºF=28ºC. These equivalencies are for temperature differences, not actual
temperatures.

9. VACUUM PROCEDURES

9.4 Sign-off of an operation is evidence/record that the procedure was followed, unless the
auditor sees evidence proving otherwise.

10. FURNACE MANFUNCTIONS/CYCLE INTERRUPTIONS

10.1 For fixed/frozen processes, this must include MRB (material review board) and a
variation. If the process is not fixed, there should be MRB. What is expected depends on
the length of the outage and the time into the cycle. “notify supervision” is not sufficient
to meet this requirement.

15
Nadcap November-2011
Coatings Task Group
Audit Handbook

Approved by the Coatings Task Group

16
Nadcap November-2011
Coatings Task Group
Audit Handbook

APPENDIX 1 – OPENING MEETING CHECKLIST

a) Scope of the Audit:

How many days
Full scope or reduced scope
Re-accreditation – initial – follow-up
Processes to be audited
Quantity and types of jobs to be audited

b) Discuss/Disclose if there are any ITAR/EAR or equivalent restrictions

c) Give a brief overview of the Nadcap NCR response expectations.

- Tell the Supplier they have 21 calendar days from the submittal of the audit to provide
their initial responses.
- Supplier is required to provide response in eAuditNet (www.eauditnet.com)

d) Staff Engineer may be contacted during audit for clarification of Nadcap requirements.

e) Make arrangements with the supplier about review of findings on a daily basis.

f) If there is an audit observer (Subscriber), explain the rules and requirements of the
observer. The observer is to only observe and not participate in the audit.

g) If there is a trainee auditor, please explain this according to Nadcap procedures.

h) Make any other arrangement necessary for smooth run of the audit:
Work hours
Any need to stay overtime
Necessary resources and facilities
Any safety considerations
Lunch (Delivery versus going out)

17