Ac7109 Rev e
Ac7109 Rev e
E
Issued 1995-03
AUDIT CRITERIA
Revised 2016-02
161Thorn Hill Road
Warrendale, PA 15086-7527 Superseding AC7109 Rev. D
TO BE USED ON AUDITS STARTING ON OR AFTER 15-MAY-2016
Nadcap
AUDIT CRITERIA FOR
COATINGS
1. SCOPE
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Copyright 2016 Performance Review Institute. All rights reserved.
t-frm-15 04-Jan-2016
PRI AC7109 Revision E -2-
Painting and Ion Vapor Deposition of Cadmium and Aluminum are not
covered by the Coatings Audit Criteria. These special processes are
part of the Chemical Processing AC7108 Audit Criteria.
2. GENERAL INSTRUCTIONS
2.1.1 The supplier shall complete a self-audit to AC7109 and all applicable
slash sheets in preparation for this audit. All nonconformances should
be corrected prior to the actual audit. Nonconformances of a technical
nature found during the actual audit may, at the Task Group's
discretion, require a follow-up audit at the supplier's expense.
2.1.1.1 During the self-audit, the supplier should note procedure numbers and
locations for all documentation required. It is recommended that all
documentation required by the Nadcap auditor is readily available to
facilitate the audit process.
2.1.2 The Task Group has compiled a set of tools to assist in the preparation
and execution of a Nadcap audit. It is strongly recommended to utilize
these tools both before and after the audit. The tools can be found in
eAuditNet/Public Documents/Coatings.
2.1.3 All audits require a "Job Audit and Test Method Tracker", herein
referred to as the Tracker, to be attached to the audit in eAuditNet. The
Tracker is a tool used by Subscribers to ensure that all processes,
tests, specifications, and Subscribers in the scope of the audit are
reviewed over a period of time.
The test method section of the tracker has been implemented to ensure
all tests in the scope of the audit are witnessed over the course of 3
consecutive audits. The tracker must be considered in audit preparation
to ensure witness tests are available during the audit so that all tests
are witnessed over the 3 audit period.
2.2.1 The supplier should provide for an in-briefing for the auditor and
arrangements for a brief plant tour prior to the start of the audit. Key
members of the applicant's staff should attend the in-briefing so the
audit purpose, methods and assessment processes, can be discussed.
2.2.2 Working space for the auditor with desks or tables, chairs, telephones,
etc. and reproduction services are to be provided as required. This is
not a full time assignment.
2.2.5 All operating parameters and tolerances used to control the process
must be available for review during the audit. For instance, if the
coating process is controlled by a program number and the parameters
used in the program are controlled in an off-site location; a copy of the
parameters must be available at the time of the Nadcap special process
audit. If this information is not available, an NCR must be written
against the requirement for defining process controls and tolerances of
process parameters.
The auditor will advise the supplier when their audit report will be
submitted and when corrective action will be due. Responsibility for
meeting this date rests with the supplier. Failure to comply with
specified dates will result in significant delays in accreditation.
PRI staff or the Task Group may, after review of the audit report,
require additional information or may elect to issue additional findings.
NOTE: Final authority over the audit report, acceptability of corrective
actions, and accreditation recommendation rests with the Task Group.
3. SUPPLIER INFORMATION
3.1 Attach a copy of the Job Audit and Test Method Tracker that includes
all Subscribers and specifications for which the supplier is
approved/processing.
The Job Audit and Test Method Tracker is a tool to ensure that all
processes, specifications, tests and Subscribers in the scope of the
audit are reviewed over time.
3.2 Has the supplier informed Nadcap of all changes that will affect the YES NO NA
Supplier's status of operation as defined in OP 1107?
PRI AC7109 Revision E -4-
3.3 Were corrective actions from previous audits implemented effectively? YES NO NA
The auditor is required to verify all findings from the previous audit
If there are any repeat findings, the answer is No
NA if this is an initial audit or if there were no NCRs in the previous
audit.
3.4 Was a self-audit completed to AC7109 and all applicable slash sheets YES NO
since the last Nadcap CT audit (or prior to an initial audit)?
The completion of the job audit section of the checklist is
recommended. Job audits can be demonstrated through alternative
methods (internal process audit, etc.)
It is recommended to review changes to the checklist requirements
when a self-audit was conducted to a previous revision of that checklist
4.1 The Nadcap Coatings Task Group recognizes all quality systems
approvals, as addressed in PD 1100. If the supplier has been audited
and approved by Nadcap or any other Nadcap recognized agency
addressed in PD 1100, then no further assessment for quality systems
will be required. Although specific audit criteria for evaluation of the
general quality system are not included within the text of this checklist,
the requirements of PD 1100 approved quality systems do form a part
of the standard used in the Nadcap Coatings Accreditation program. As
such, auditors may identify and record nonconformances related to the
quality system. These nonconformances must be addressed by the
supplier in order to obtain Nadcap Accreditation.
The auditor shall verify the supplier has a valid quality system certificate
or otherwise in compliance with Nadcap procedures. A copy of the
certificate does not need to be attached in the audit report.
4.1.1 Is the supplier compliant with approved Quality System as observed in YES NO
the scope of this audit?
A No would be for any quality system violation which is identified which
is not addressed by other questions in the checklists
Examples: Uncontrolled document,
4.1.2 Supplier personnel associated with the audit aside from the Supplier _______________
Audit Contact:
4.2 Organization
4.2.3 Are all of the designated coating operators (thermal spray, vapor YES NO
deposition, diffusion) currently certified (when required by the customer)
or otherwise approved in accordance with supplier procedures?
Department training records, personnel file. Must be some certification
or approval on record.
4.2.5 Does a defined representative approve all active coating operators? YES NO
4.2.6 Are records maintained for all active coating operators? YES NO
4.3.2 Do procedures assure that the supplier verifies they have the required YES NO
approvals prior to performing the process?
Some denotation in the system that approval is required before
production may proceed. Could be note on router, procedure for issuing
router, part of the First Article Inspection Report (FAIR) approval
process or specific reference in procedure for fixed process
manufacturing.
4.3.3 Are coating trials conducted prior to initial use of coating on production YES NO NA
hardware to ensure the coating will meet material/process
specifications?
PRI AC7109 Revision E -6-
4.3.5 Does the supplier have approved technical plans/processes for YES NO
hardware, including customer approval when required?
Looking for more definition of the process than simply a router listing.
Each critical operation should have functional requirements specified by
process and/or configuration. Could be in the form of both higher level
operational procedures and part specific operational sheets.
4.3.6 Are all internal procedures referenced in the task-specific work YES NO
instructions available to the operator?
Looking for a direct reference to the internal procedure in the router or
the work instructions. Verify that procedures are available to the
individual performing the task.
4.4.1 Do procedures require that documentation (e.g., traveler) detailing each YES NO
operation accompanies each job?
Looking for a reference in procedures as to what functional
requirements are stated at the manufacturing level either by
departmental procedures or job specific operation sheets.
4.4.2 Are relevant work instructions available in each work area? YES NO
Work instructions can be embedded in router, posted at the booth,
available at a computer workstation in the area or master book of
operational procedures in the department.
4.5.1 Does the supplier have a procedure, including appropriate marking of YES NO NA
shop job documents, which assures that fixed process changes are
made only after receipt of required approvals from the customer?
Review document control procedure, router revision control
documents, FAIR or fixed process change control procedures.
NA if no fixed process is required by the customer.
4.7.2 Do records demonstrate that samples are taken in accordance with the YES NO
specified sampling plan?
5.1.2 Are there records that indicate that maintenance is performed in YES NO
accordance with the procedures?
5.2.1 Is there a procedure that specifies the control and identification of test YES NO
materials and specimens, as well as when and where they are to be
used?
Procedure and work instruction review, looking for a specific reference
on control of test material, check for meeting customer requirements.
Specimen must be identifiable to material type
Labeled bins, color coding, different sizes, etc. are examples of
acceptable control and identification
5.2.2 Are coated test specimens traceable to the work order, part(s), process YES NO
validation or equipment at least until testing is complete?
Traveler, envelope, etc.
The test specimen must be traceable back to the work which it
represents
Validate that test material as it is separated from the parts for
evaluation has proper designation to relate back to the production batch
or lot.
5.2.4 Is production coating evaluation, applicable to PRI AC7109/5, with the YES NO
exception of microanalysis of coating composition, performed by a PRI
AC7109/5 Nadcap-accredited laboratory?
This requirement applies to tests performed internally and tests that
are outsourced. For example if the tensile test is outsourced, the lab
performing the tensile test must be accredited to AC 7109/5.
5.2.4.2 For testing performed externally, is there evidence of a system for YES NO NA
reviewing reported test results for compliance to customer
requirements?
NA applies when tests are not performed externally
Technique employed that verifies results are evaluated as
acceptable/unacceptable. (tick marks, log sheet, procedure,
stamp/sign-off or other methods such as electronic verification)
5.3 Calibration
5.3.1.1 All shop equipment used to control or monitor control of a process? YES NO
Specific equipment calibration requirements are referenced in the
applicable audit criteria e.g. AC7109/1 Appendix 1.
Calibration is required over the range of use except in cases where
there are no commercially available standards that cover the entire
range of use.
Calibration is not required for tape measures or rulers used to
measure standoff distance.
The expectation is timers must be calibrated when seconds are
important. An example where calibration is required: timer [e.g. stop
watch] used to determine powder feed rate. An example where
calibration is not required: timer [wall clock] used to determine the
elapsed time between grit blast and thermal spray operations.
5.3.1.2 All test and inspection equipment used to accept product or control a YES NO
process?
Calibration is not required for specimen preparation equipment used in
AC7109/5.
The expectation is that surface profilometers are to be calibrated.
5.3.2 Are pre- and post-calibration data recorded when adjustments are YES NO NA
made?
PRI AC7109 Revision E -9-
5.3.3 Is there record of actions taken in the event calibration is found outside YES NO NA
of allowed tolerance?
Not applicable if no out of tolerance calibrations have occurred
6.1 Is there evidence that the supplier has provided the methods and YES NO
means of handling and protection from receiving through shipping?
7.1 Does the supplier have a method for controlling the removal of YES NO
coatings?
7.2 Are the number of strip cycles approved and are they each documented YES NO
and traceable to the hardware?
Customer and specification requirements for cycles that may include
approval of method in general or part specific approval
7.3 Are the reasons for coating removal recorded on the individual part/lot YES NO
documentation, the rework properly authorized and the need for
corrective action considered?
Documentation may include Non-Conformance Report (NCR) form,
rework form, or incoming paperwork where stripping is part of work
scope.
Proper authorization may vary depending on the reason for coating
removal. For example, coating removal due to an in process rework of
original equipment, may require authorization from the design authority
(cognizant engineering authority, customer). For repair situations,
proper authorization may be the customer order.
Corrective action must be considered only in the case where coating is
removed due to in process rework of discrepant coating.
7.4.1.1 Does the supplier have suitable equipment to perform the stripping? YES NO
Design Authority Approvals, Specifications, Internal requirements for
equipment
7.4.2.1 Does the supplier have approved (internal or by customer when YES NO
required) procedures and/or work instructions for each stripping
method, describing each step in the stripping process?
Chemical stripping generally requires customer approval
Validate a stripping procedure has been evaluated and approved
either by customer, design authority or internal authority.
7.4.2.2.6 Methods of protection against corrosion with appropriate time limits for YES NO NA
protecting parts?
7.4.2.3 Does the supplier use control methods to monitor significant operational YES NO
parameters?
Any charting or recording of parameters, electronic controller,
software, regulator
7.4.2.4 Does the supplier have defined inspection procedures to evaluate YES NO
stripped hardware?
Described on router and/or in procedure or work instruction
7.4.3 Are controls (e.g., inspection, frozen parameters, training, documented YES NO
procedures) in place to ensure the base material is protected from
excessive erosion during coating removal?
7.4.4.1 Are procedures used for post-strip cleaning clearly defined (e.g., YES NO
compressed air/water spray rinse)?
PRI AC7109 Revision E - 11 -
7.5.1 If the supplier performs embrittlement relief, are they accredtited to PRI YES NO
AC7109/7 or PRI AC7102?
8. COMPLIANCE
A minimum of one job audit is required for each slash sheet which
includes job audits. A minimum of two total coating process job audits
must be performed: If the scope of the audit only contains one coating
process slash sheet (AC7109/1, /2, /3), two job audits must be
performed for that slash sheet. At least one of the job audits must be an
in-process job audit with the preference being that all job audits are in-
process work. Staff Engineer and/or Nadcap Coatings Task Group
approval are required for performing fewer job audits than required.