Maintenance Repair & Overhaul (MRO)Business Case

Nadcap/NUCAP OEM Subscriber Experience

Revision Date: 15 May 2014

Contents• Nadcap Global Acceptance• Background • Nadcap Benefits

– OEMs– Suppliers

• Benefits of Nadcap Approach• Business Case Objective• Chronology• Sequence for Expansion of

Nadcap into MRO• MRO Areas to be considered

by Nadcap Subscribers

• Survey of Existing Nadcap Subscribers

• Supply Chain Deployment• Case Study• Perceived Myths• Challenges in the MRO

Community• Gap Analysis• Cost & ROI• For More Information• Acronyms

Background• Redundant audit activity exists in the Maintenance Repair &

Overhaul (MRO) world• The requirements are just as stringent for MROs as OEMs• Nadcap improved controls in the OEM world, and there is a value

in demonstrating these same kind of improvements in the MRO world as well

• In some cases, MRO manuals and OEM specifications may not be aligned

• There are more opportunities for rebuild and repair cycles in the MRO industry than the OEM industry, therefore increasing the chance of escapes, re-work, and cost.

4

Nadcap Benefits to OEMs• Global Supply Chain managed through a single real-time on-line system for the

entire industry allowing companies to better manage supplier-associated data (eAuditNet)

• eAuditNet supports procurement to identify accredited suppliers (Qualified Manufacturers List)

• Conduct more in-depth, technically superior special process audits• Increases number of consistent audits of the supply chain• Establish stringent industry consensus standards that satisfy the requirements of all

participants• Identify and reduce risk of exposure to lower-quality suppliers • Provides industry-wide early warning advisories for potential product impact and

escapes (defective products)• Provides complete visibility of supplier behaviors and transparency of audit results

in a secure and retrievable format• Program reduces costs of supply chain oversight and control• Utilizes technically superior auditors to assure process familiarity• Effectiveness of OEM’s Quality team increased – able to look beyond baseline

requirements and focus on problem areas (special processes) and suppliers• Improves flow down of industry and customer requirements to sub-tier suppliers

5

• Provides routine special process audits accepted by industry• *85% report supplier quality improvements after accreditation,

including more than one-third reducing scrap rates, reworks and escapes (defective products)

• Promotes lean and continuous improvement practices, leading to higher quality and lower overall cost

• Industry accepted and consistent technical requirements leading to uniform process controls and greater operational efficiency

• Develops a structured approach to special process and product manufacturing

• Can use accreditation to increase client-base• Improves customer relationship, technical support, and training.• Improves Program/Special Processes predictability.• Increases visibility to subscribing OEM base.• Opportunity to participate in development of audit criteria and

program operations

Nadcap Benefits to Suppliers

*Aerospace data

Benefits of the Nadcap Approach• End users become more aware of the importance of their

processes• This activity becomes an integral part of internal risk reduction

activity• Aids in identifying clear ownership for each Special Process• Enables improved levels of Process Control• Introduces standardisation of the Controlling Procedures across

sites• Encourages cross functional team working• Provides the vehicle to implement focused improvements to

processes• Key strategic improvement, with visibility at a senior level within

the organisation• Following re-accreditation, sites can focus on Process Flow &

Process Capability• Improves first pass yield• Improves operating approach, compliance, training,

communication and alignment of resources.

Business Case ObjectiveThe purpose of this Business Case package is to demonstrate to Nadcap/NUCAP (Nadcap Users Compliance and Accreditation Program) Subscribing OEMs the value of utilizing the Nadcap/NUCAP accreditation program in their internal MRO facilities that reduces risk, increases compliance to approved data and with airline support will reduce the number of redundant audits and improve process understanding.

The ultimate objective is to drive Nadcap/NUCAP across the entire MRO community.

Chronology• 2010-2011

– At PRI Board of Directors request, a PRI staff team began to investigate where the Nadcap model may be applicable for the MRO Industry

– PRI conducted research, presented at industry events, and developed relationships with industry stakeholders (Nadcap OEMs, CASE, airlines, MRO shops, etc.)

• 2012– Rolls-Royce presented to the Nadcap Management Council (NMC) on their

implementation of NUCAP in their MRO facilities (Feb12)– An NMC sub team was launched to explore Subscriber interest & possible

support - 12 Subscribers joined – bi-monthly meetings– Sub-team survey was conducted to determine level of interest and

potential scope – results were favorable

• 2013-2014– Some existing Nadcap/NUCAP companies began using Nadcap/NUCAP

internally for their MRO facilities

Sequence for the Expansion of Nadcap/NUCAP into MRO

Step 1. Existing Nadcap/NUCAP Subscribers’ own MRO Facilities. Gain regulatory agency recognition.Step 2. Existing Nadcap/NUCAP Subscribers’ MRO Service Providers (those who are already Nadcap/NUCAP accredited Suppliers)Step 3. Existing Nadcap/NUCAP Subscribers’ MRO Service Providers (those who are not Nadcap/NUCAP accredited Suppliers)Step 4. Part 145 Repair Stations (Non-Nadcap Subscribers)

Sequence for the Expansion of Nadcap/NUCAP into MRO

OEM’s MRO facilities (gain regulatory

recognition)

Part 145 Repair Stations

Engage Airlines and Lease Holders

Suppliers to OEM’s MRO facilities

2012 2013 2014 2015 2016 2017 2018

MRO Areas to be Considered by Nadcap/NUCAP Subscribers:

– Contract with airline for maintenance – All components come from OEM side (Nadcap/NUCAP or OEM suppliers)

– MRO shops on OEM sites – Majority of Special Processes done by Nadcap/NUCAP

– Major stand-alone structural/overhaul MRO shops

– Component repair supply vendors

– Sites where primary OEM and MRO distinction is being combined or united

Survey Conducted of Existing Nadcap/NUCAP Subscribers

Special Processes within Subscriber internal MRO shops where currently self-imposing Nadcap/NUCAP:

Commodity Number of OEMs OEM CompaniesNon Destructive Testing (NDT) 4 Goodrich (UTAS), Honeywell, Rolls-

Royce, SAFRANChemical Processing (CP) 3 Honeywell, Rolls-Royce, SAFRANHeat Treating (HT) 2 Rolls-Royce, SAFRANCoatings (CT) 2 Rolls-Royce, SAFRANNonconventional Machining & Surface Enhancement (NMSE)

1 Rolls-Royce

Welding (WLD) 1 Rolls-Royce

* Data from 2012 NMC MRO Sub-Team Survey (10 Subscribing OEM responses)** There may be additional Special Processes and participating Subscribers not listed in the above chart, as eAuditNet only recently began differentiating between OEM and MRO audits

Current Use of Nadcap in the MRO Community

• Current Nadcap/NUCAP Subscriber internal MRO shops with accreditation (NMC MRO Sub-Team Survey Data - 2012)– 5 Subscribers self-impose Nadcap/NUCAP on their internal MRO shops– Commodities: CP, CT, HT, NDT, NMSE, WLD

• Nadcap/NUCAP suppliers doing work for MRO shops (Self-identified in eAuditNet system – 15 April 2014):– Suppliers: 14– Subscriber Suppliers: 4– Accreditations: 31– Commodities: AQS, CMSP, CP, CT HT, MTL, NDT, NMMT, SE, WLD– Countries: Canada, Hong Kong, UK, USA, Singapore, South Korea, Spain

• Nadcap/NUCAP suppliers doing work for MRO and OEM shops (Self-identified in eAuditNet system – 15 April 2014):– Suppliers: 51– Accreditations: 55– Commodities: AQS, CMSP, CP, CT HT, MTL, NDT, NMMT, SE, WLD– Countries: Australia, Belgium, Canada, China, Hong Kong, India, Italy, Japan, Mexico, Philippines, UK, USA,

Singapore, South Korea, Spain, Taiwan

Supply Chain DeploymentSome Nadcap OEMs have begun to flow MRO into the supply chainRolls-Royce made a policy decision to

mandate on the MRO supply chainMRO suppliers to gain Nadcap

accreditation in:• NDT (PT, RT MT)• Chemical Processing• Heat Treatment• 1 process by end of 2012• 3 processes by end of 2013

Targeted at ~60 suppliers (Planned for 50% uptake)

• ~ 30 NDT audits in 2012• ~ 30 NDT, CP & HT audits

in 2013

Supply Chain Deployment• Special Processes

– NDT is used in every MRO activity

– Evaluate other special processes based on frequency of MRO activity:

• CP, HT, CT, NMSE, WLD

• Risk Assessment Criteria– Part criticality– Process activity– Compliance to Repair

Manual Requirements– Cost of non-quality due to

special process– Known in-service issues– Special Process criticality

Case StudyNadcap/NUCAP Subscriber with 2 MRO Facilities:

Background: Subscriber major overhaul center, NDT, Weld, Heat Treat & Chemical ProcessingFindings:1. Experienced a large learning curve when earning

Nadcap accreditation• The Nadcap audit methodology is very different than any other

audit the site had experienced, depth of audit into the specific processes

2. NDT Audit • Prior to audit, facility did not see value • After the audit, facility recognized the reduction in risk

– Number of Findings– Severity of Findings– Value of the audit methodology

Perceived Myths• Myth: New MRO-specific checklists must be created

– Fact: The current Nadcap checklists for NDT, CP, HT and CT were effectively utilized in Rolls-Royce’ experience.

– Supplemental checklists to be modified for individual OEMs• Myth: Will increase internal costs with no business benefit

– Fact: Nadcap is a risk reduction activity (cost avoidance). There are slight increases in direct costs (e.g. participation fees) with considerable decreases in indirect costs (e.g. manpower) for subscribers. Nadcap is a shared cost approach.

• Myth: Not applicable to MRO– Fact: Audit checklists are specific to the special process as defined by industry

specifications and are not specific to OEM or MRO. Checklists are the essence of good special process controls. There are MRO equivalents to OEM: 9100/9110; PO/FAA return ticket, technical publications; process spec/maintenance manual

• Myth: Will make MROs uncompetitive– Fact: Creates a competitive edge/benefit for accredited suppliers. It opens up the market

for increased opportunities for suppliers who meet Nadcap accreditation.• Myth: Not formally recognized within the MRO Industry

– Fact: Nadcap has only been recently expanded into subscriber MRO facilities. Since Nadcap is widely recognized among OEMs & Regulatory Bodies globally, it should enable a smooth transition into the M RO community.

Challenges in the MRO Community that will need to be Considered for

Nadcap/NUCAP Deployment• Standard Practise Manuals do not define all requirements. • Lower level procedures inadequate or unavailable• Technical Instruction content inadequate • Inadequate document cascade: blue print process

specifications shop floor instructions• Operator training and approval practises varied across sites• Pyrometry - Insufficient knowledge of AMS2750• Preventative Maintenance activities inadequate• No flow-down requirements exist• No advanced forecasting available

* No difference from what is seen in OEM / supply chain areas and are all areas of potential quality failures that could be rectified through the Nadcap audit and NCR close out process.

Cost & ROI• Cost

– Nadcap Subscriber fees: • Contact PRI’s Supplier & Subscriber Services Supervisor - +1 724

772 1616– Nadcap audit:

• www.eauditnet.com Documents Public Documents General Documents “Audit Pricing Sheet”

– Audit preparation: • Will vary for each MRO based on current practices in relation to the

audit checklist

• ROI– Every OEM in Nadcap/NUCAP currently utilizes the program in a

different way. The ROI is different for each OEM in relationship to their contribution and participation level.

For more information

Scott KlavonDirector, Nadcap Program & Aerospace Operations, PRI

sklavon@p-r-i.org+1 724 772 7111

Seema MartinDirector, European

Operations, PRIsmartin@p-r-i.org+44 20 7034 1243

Justin McCabeResearch & Development

Specialist, PRIjmccabe@p-r-i.org+1 724 772 8693

Acronyms• AQS – Aerospace Quality System • CASE – Coordinating Agency for Supplier Evaluation• CP – Chemical Processing• CT – Coatings• FAA – Federal Aviation Administration• HT – Heat Treating• OEM – Original Equipment Manufacturer• MRO – Maintenance Repair & Overhaul• NMSE – Nonconventional Machining & Surface Enhancement• NDT – Non-destructive Testing

– MT - Magnetic Particle – PT - Penetrant– RT– Radiography

• NMC – Nadcap Management Council• NUCAP – Nadcap Users Compliance and Audit Program• ROI – Return on Investment• WLD – Welding