The True Cost of Becoming Aerospace Accredited
Heat Treater Furnaces North America
Tuesday October 7th 2014
10:30-11am
Bob Hill
President
Solar Atmospheres of Western PA
Heat Treatment of Yesterday
Courtesy of Surface Combustion Courtesy of Surface Combustion
Heat Treatment of Today
Courtesy of Surface Combustion Courtesy of Surface Combustion
Instrumentation of Yesterday
Instrumentation of Today
Pyrometric Tools of Yesterday
Pyrometric Tools of Today
Today Quality Accreditations are Driving Perfection
NADCAP
ISO
Boeing
The Heat Treaters Bible (Including Aerospace) AMS 2750E
Temperature Uniformity Surveys Validates the proper functioning & limitations of any heat
treat furnace
Operator Training Programs
Detailed procedures, records, and statements of limitations regarding personnel
Procedures: Equipment Capability Pyrometry Furnace Operations Preventative Maintenance Contract Review Technical Instructions to shop floor Testing and Reporting Results Non Conformances Control of Records
Purchasing Control of critical supplies
T/Cs Specialty Gases Capital Equipment
Control the purchase of Heat Treating Services Proper Flow down of Information
AMS Specifications Complete and well vetted documents that
control the heat treatment of most metals in a uniform and well tested environment
Value Added Support Services
The Cost of Quality is Not Cheap!
Yearly Costs of Nadcap /AS/ISO Quality 5 Quality FTEs $450K TUS Costs $150K Procedural Costs
Bake Outs (bi monthly) $550K Leak Up Rates (weekly) $550K Calibrations $10K
Third Party Audit Costs (travel) $20K Additional Thermocouple costs $83K Additional Testing Equipment $150K Level III NDT Consultant $11K IT Related Costs $10K
Total Costs = $1,984,000 (approx. 13% of total sales)
This Does Not Include Auditing Costs Associated with Primes
Airbus Boeing Lockheed GE Honeywell Safran Pratt & Whitney
UTC Aerospace Space X Northrup Grumman Hamilton Sundstrand Parker Aerospace Sikorsky Rolls Royce
Not to Mention Sub Primes
This Does Not Include Supply Chain Requirement Costs:
ITAR / EAR Registrations Exostar Registrations EDI (Electronic Data Interchange) Barcode Scanning Training:
SCA (Source Certifying Agent) CHTR (Certified Heat Treating Representatives) DQR (Designated Quality Representative)
My Opinion:
Heat Treat Accreditations are NOT going away!
Todays Heat Treating Market
North American MTI Commericals Nadcap Accredited = 52 out of 269
North American Captives and Commericals
Nadcap Accredited = 492
The Ultimate Goal of an Aerospace Engineer is to increase passenger
safety
Nadcap Global Recognition
1 5 6 6 7
10 10 14 17
19 21 26
30 32 33 30 31 30 31 29
1 2 2 3
3 3
5
12
16
18 18 19 20 20 20 21 21
1 1
1 1
0
10
20
30
40
50
60
1990 1991 1992 1994 1995 1998 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
South America
Asia
Europe
North America
Nadcap Evidence of Increasing Quality
Chart1
2772
3111
3385
3696
3945
4112
Number of suppliers on merit
Sheet1
Number of suppliers on merit
20092772
20103111
20113385
20123696
20133945
20144112
To resize chart data range, drag lower right corner of range.
Nadcap Positive Supplier Feedback
25%
77% 76%83% 85%
0%20%40%60%80%
100%
2003 2005 2007 2009 2011
Quality Increase
*2011 SSC Supplier Survey*
Chart1
25
77
76
83
85
Quality Increase
Sheet1
Quality Increase
200325
200577
200776
200983
201185
Nadcap Improved Performance
*2011 SSC Supplier Survey*
Nadcap Improved Commercial Opportunity
*2011 SSC Supplier Survey*
Other Industries are Joining In
Top Ten Keys to Quality & Compliance 1) Minimize Employee Turnover 2) Know the PRI checklist by memory 3) Take copious notes on the checklist & save it for next audit 4) Have every employee perform an internal audit on a job 5) Scrutinize every aerospace job prior to shipping 6) Attend the Nadcap annual meetings in October
9) Top management must lead this effort! 10) Network with other Heat Treaters
8) Review past findings & make sure they are not repeated
7) Plan preparation meetings 6 months prior to your audit. Dont procrastinate!
THE MTI IS HERE TO HELP YOU!
Questions? Bob Hill [email protected]
Slide Number 1Heat Treatment of YesterdayHeat Treatment of TodayInstrumentation of YesterdayInstrumentation of TodayPyrometric Tools of YesterdayPyrometric Tools of TodayToday Quality Accreditations are Driving Perfection Temperature Uniformity Surveys Operator Training ProgramsProcedures:PurchasingAMS Specifications Value Added Support ServicesThe Cost of Quality is Not Cheap!Yearly Costs of Nadcap /AS/ISO QualityThis Does Not Include Auditing Costs Associated with PrimesThis Does Not Include Supply Chain Requirement Costs:My Opinion:Todays Heat Treating MarketThe Ultimate Goal of an Aerospace Engineer is to increase passenger safetySlide Number 23Nadcap Global RecognitionNadcap Evidence of Increasing QualityNadcap Positive Supplier FeedbackNadcap Improved PerformanceNadcap Improved Commercial OpportunityOther Industries are Joining InTop Ten Keys to Quality & ComplianceThe MTI is here to help you!