AC7114/5

AUDIT CRITERIA
161Thorn Hill Road Warrendale, PA 15086-7527

Issued 2012-3 Revised N/A Superseding N/A

TO BE USED FOR AUDITS ON OR AFTER JULY 01, 2012 Nadcap AUDIT CRITERIA FOR NONDESTRUCTIVE TESTING FACILITY EDDY CURRENT SURVEY

1.0

SCOPE
These Audit Criteria define the requirements for suppliers seeking Nadcap accreditation in Eddy Current and are to be used as supplement to PRI AC7114. These criteria and the applicable User Prime Supplemental Checklists will ensure that NDT suppliers meet the requirements for Nadcap accreditation in Eddy Current.

2.0

GENERAL INFORMATION
In completing this assessment, auditors are instructed to respond with a "Yes or No" to address compliance with each statement of requirement. For any negative responses, the auditor must clearly indicate in the NCR if the No" reflects noncompliance with respect to existence, adequacy, and/or compliance. Existence relates to evidence of a documented procedure or policy, adequacy relates to the completeness of the procedure or policy, and compliance relates to evidence of effective implementation. This checklist includes the use of the word shall which indicates a clear requirement that must be met at all times. The word, may indicates a possible resolution to a requirement or one recommended method to achieve a given requirement, but does not represent the only way to meet that requirement. In addition the checklist includes the term Compliance Assessment Guidance. This term is used to reflect the Task Groups expectation when answering the checklist question as YES or N/A. The auditor must verify the list of procedures provided by the supplier at the time of the audit. Any corrections or updates to the list must be identified using notes inserted at the applicable criterion. All negative responses require a Nonconformance Report (NCR). Not Applicable (N/A) responses do not require an explanation unless otherwise noted. There is only one plausible reason for an N/A, which is, that a particular operation or issue is not being used at the supplier. There are no N/As simply for a lack of a customer requirement. If a system is in use, then all questions pertaining to that system are applicable. If verification of results require documentation it shall be so noted in this checklist. The audit results shall not include any customer proprietary information. Technical information on parts which have been designated Export Controlled License Required (EC-LR) cannot be input into eAuditNet. If auditors have any questions about this, they should contact the Staff Engineer for directions. GO FORWARD PLAN Any new or revised procedure made after 17 February 2012 requires compliance to the following requirements. Procedures written prior to this date shall be acceptable; however a system needs to be in place to ensure that changes reflect the current Nadcap requirements.

PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and quality sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there from, is the sole responsibility of the user." PRI values your input. To provide feedback on this document, please contact the appropriate commodity staff engineer. (Contact information is located at http://www.eauditnet.com under Contact Us.) Copyright 2012 Performance Review Institute. All rights reserved. t-frm-15

3-Jan-12

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2.1 References SAE Publications: AS7003

AC7114/5

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Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15086-0001 Nadcap Program Requirements

3.0
3.1

MATERIALS AND EQUIPMENT

Materials, Equipment Listing and Information The supplier shall complete and the auditor shall review the supplier's provided materials and equipment listing, for adequacy, content and correctness. Attachments are for information only but shall be completed fully. NCRs shall not be written against attachments. (Attachment AC7114/5-A). 3.1.1 Is a current calibration certificate or metrology verification available for the eddy current instrument Are all probes identified, or provide traceability to, part number, frequency, coil diameter and if the probe coil is shielded or un-shielded? Compliance Assessment Guidance: The type and frequency may be traceable via the part number. 3.1.3 Is/are the magnetometer/residual field indicator(s) used to verify demagnetization, calibrated at a minimum of one point in the range of use at least semi-annually? Compliance Assessment Guidance: If yes, answer the following questions under Subsection 3.1.3 If ferrous materials/parts are not eddy current inspected, answer N/A to this sub-section. 3.1.3.1 Does/do the field strength meter(s) have valid calibration certification? YES NO YES NO N/A Attachment

YES NO

3.1.2

YES NO

3.2

Reference/Calibration Standards and Documentation 3.2.1 Is documentation available for all reference/calibration standards fabricated in accordance with Subscriber specifications? For special standards, is the standard comparable to the component being inspected, including surface finish? 3.2.2.1 3.2.3 Is there manufacturing documentation available? YES NO

3.2.2

YES NO NA

YES NO YES NO

Are all standards clearly identified as to material type, notch size and depth, etc. or traceable to documentation with noted requirements? Is the reference standard representative of the bearing configuration being inspected, per technique/procedure? Compliance Assessment Guidance: Material, inner ring verses outer ring, spherical raceway verses flat, size etc.

3.2.4

YES NO N/A

3.2.5

Are reference/calibration standards stored and handled to prevent damage from mishandling, corrosion, pitting, etc.?

YES NO

4.0
4.1

PROCEDURES
NDT Facility Written Procedures

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4.1.1

AC7114/5
Is there a procedure, general or specific, for processing and inspection covering the Eddy Current testing method?

-3YES NO

4.2

Approval 4.2.1 Does the procedure(s) indicate approval by the applicable Level 3? Compliance Assessment Guidance: The applicable Level 3 may be the Nadcap User, Nadcap User qualified or approved Level 3, internal Level 3 and/or external Level 3. YES NO

4.3

Procedure / Technique Does the written procedure, general or specific, contain the following information as a minimum? Compliance Assessment Guidance: The term, procedure may be synonymous with a traveler or a route card, automatic scan plan etc. All non-technical requirements that have been flowed down solely by the baseline will only be required to be met if that in-use technique or process has been revised since the inception of the baseline on Month, Day, Year Traceability to the name and address of the facility performing the inspection? Compliance Assessment Guidance: In some cases it may not be necessary for the actual address as long as the facility is traceable to a unique identifier. 4.3.2 4.3.3 Procedure identification number and the date the procedure was approved? A requirement that all personnel are qualified and certified to the required level for the activity undertaken and the applicable contract requirements? Does this technique/instruction include part number, material, alloy, type relevant to the material / part to be examined? Equipment to be used for inspection, including manufacturer and model number? Frequency, coil diameter, shielded/un-shielded and type (or part number) of probes used? Compliance Assessment Guidance: The type and frequency may be traceable via the part number. 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11 Reference standard identification Reference standard and material/part demagnetization requirements? Use of magnetic field indicators to verify demagnetization? Address or provide traceability to customer acceptance criteria? Required calibration parameters? Compliance Assessment Guidance: For example, minimum amplitude settings" for notch response and "gating requirements" for flaw detection. YES NO YES NO N/A YES NO N/A YES NO YES NO YES NO YES NO

4.3.1

YES NO

4.3.4

YES NO

4.3.5 4.3.6

YES NO YES NO

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4.3.12 4.3.13 Minimum signal to noise ratio?

AC7114/5

-4YES NO YES NO

Sketches, photos, or chart, indicating the inspection area and coverage and/or orientation of the material/part? Does the technique/instruction include Internal Filter Setting Used? Does the technique/instruction include External Filter Setting Used? Inspection index increments, scan speed and inspection coverage verification method used? Acceptance requirements to be used for evaluating indications and disposition of part(s) after examination? Description for the method of identifying inspection status? Method for the control of software or programming used for automated processing equipment as applicable? Compliance Assessment Guidance: This would include software used to control automated systems.

4.3.14 4.3.15 4.3.16

YES NO N/A YES NO N/A YES NO

4.3.17

YES NO

4.3.18 4.3.19

YES NO YES NO N/A

4.3.20

All required equipment standardization checks called out in section 5 of this checklist?

YES NO

5.0

EDDY CURRENT EQUIPMENT STANDARDIZATION

Compliance Assessment Guidance: If a particular system is not used by the supplier, (i.e., Conductivity Testing) then questions pertaining to that system are N/A and no explanation is required. Where equipment is not used for a period in excess of the check frequency, the check shall be performed immediately prior to use. If the following process control checks are performed at the supplier, adequate procedural coverage is expected to be evident and is to be reviewed by the auditor. If the tests are performed by an external source, the auditor is expected to review evidence of flow-down (i.e., a Purchase Order) with the appropriate information to include at a minimum; traceability to the required test and the standard used. In addition an adequate certification or other document is required to document the results of the tests.

5.1

Equipment Standardization 5.1.1 Does the standardization/calibration reflect the requirements given in the technique? YES NO

5.1.2

Is the surface roughness of the standard such that the customer required defect signal to noise ratio is maintained? Are the inspection scanning parameters used to inspect material/parts the same as those used on the reference standard? Do the ends of the probes employ a protective barrier to eliminate scratches on parts under inspection; e.g., Teflon tape, etc. as required by the customers specification? Compliance Assessment Guidance: N/A is only to be used where the probe is not in contact with the parts surface or when not required by the specification.

YES NO

5.1.3

YES NO

5.1.4

YES NO N/A

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5.1.5

AC7114/5
Is the lift-off distance between the probe and material/part the same as the standardization as listed in paragraph 5.1.1? Compliance Assessment Guidance: As required by the approved technique. 5.1.6 If bolt hole probes, encircling and/or inside diameter coils are used, is the fill factor between probes and material/parts within +/-10% of the reference standard as listed in paragraph 5.1.1?

-5YES NO

YES NO N/A

5.2

Equipment and Material Performance 5.2.1 Is the system checked at the beginning of the examination, whenever there is a change in equipment or accessories, whenever there are changes in the electrical power supply that affect the eddy current examination, after 4 hours, at the end of the shift, at the end of the lot (automated inspection equipment) or at the end of the inspection? Compliance Assessment Guidance: This shall be defined by procedure. 5.2.2 For automated systems is the system calibrated in accordance to the customer requirements? Compliance Assessment Guidance: This includes robotic systems YES NO N/A YES NO

6.0

COMPLIANCE
Compliance Assessment Guidance: The supplier shall perform representative inspections from current production to determine compliance with these requirements. These parts shall be selected to represent a variety of Nadcap participating customer requirements and several different types of processing equipment if more than one Eddy Current system is in use at this facility. Borrowing hardware from one company to another to demonstrate compliance is not acceptable; unless there is objective evidence the design authority has authorized movement of the hardware to the company undergoing the audit. Investigate the purchase order specifications to identify any customer unique acceptance, process control, or procedure requirements applicable to these parts. Witness the facilitys ability to perform inspection of these parts in accordance with the requirements. It is expected that the auditor shall review and follow traceability from the purchase order to completion of the NDT process or final certification by reviewing as a minimum the items listed below. The auditor shall verify that the process applied complies with the procedural system established by the company in terms of flow down, customer specification retrieval (as applicable), inspection identification, etc. a) Purchase Order b) Drawing (if applicable) c) Work Order d) Process Specifications and Revision e) Internal Procedures and Revision f) Lot / Batch / Serial Number: g) Applicable Procedures / Techniques / Work Instructions h) Travelers / Route Cards i) Inspection Log

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6.1

AC7114/5

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Provide the following documentation for auditor review for each of the parts being tested during the compliance portion of the audit: Note: EC-LR materials shall not leave the suppliers facility. a. Copy of completed technique card or supplier procedure cover page with evidence of customer approval if required. Copy of the applicable page from the completed shop traveler or work order. If neither a or b above indicate the process and acceptance standard and their revision status, then the document that shows the link to this data shall also be reviewed.

b. c.

A. Customer

Compliance YES NO End User

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

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AC7114/5

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Part Number:

Revision

Inspectors

Level(s):

B. Customer

Compliance YES NO End User

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

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AC7114/5

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Inspectors

Level(s):

C. Customer End User

Compliance YES NO

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

Inspectors

Level(s):

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AC7114/5

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6.2

If applicable and in conjunction with the preceding, the supplier shall also provide an additional three paperwork compliance jobs across the Nadcap User base. Provide the following documentation for auditor review for each of these jobs: Note: The goal is to provide at least one set of compliance documentation for each of the suppliers Nadcap User customer base. If all of the suppliers Nadcap customers were represented in the actual compliance audits, then this section is N/A. Note: EC-LR materials shall not leave the suppliers facility. a. Copy of completed technique card or supplier procedure cover page with evidence of customer approval if required. Copy of completed shop traveler or work order. If neither a or b above indicate the process and acceptance standard and their revision status, then the document that shows the link to this data shall also be reviewed.

N/A

b. c.

A. Customer

Compliance YES NO End User

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

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AC7114/5

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Part Number:

Revision

Inspectors

Level(s):

B. Customer

Compliance YES NO End User

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

Inspectors

Level(s):

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AC7114/5

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C. Customer End User

Compliance YES NO

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

Inspectors

Level(s):

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AC7114/5

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6.3

Customer Specifications Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.3.1 Is the facility using the appropriate specifications and revisions as required by the contract document? Compliance Assessment Guidance: This will be confirmed by the auditor by reviewing the customer P.O. and End User drawing if available. 6.3.2 If the facility is working to any deviations, have they been approved by the customer? Compliance Assessment Guidance: The auditor will confirm documented customer approval; this may be in the form of a written communication, technique approval or by a formal deviation from the End User. 6.3.3 Were the applicable requirements, procedures and acceptance criteria made available to the Eddy Current inspectors? Compliance Assessment Guidance: Work instructions/routings/shop travelers/techniques/procedures, acceptance criteria and unique customer requirements shall be available to the inspectors. The term available means that these documents are within easy access by the technicians. These documents are available and are used to perform the inspections, not used from memory. 6.3.4 If written procedures, and or techniques, require review and/or approval by the Cognizant Engineering Organization, is that approval evident? Compliance Assessment Guidance: This shall be investigated and confirmed by the auditor by reviewing the last ten part numbers shipped. 6.3.5 If applicable, are part specific drawing inspection and/or acceptance notes being flowed down and followed by the inspectors? Was there evidence of compliance to the document control procedure? If applicable, are all specifications, drawings, procedures or technique changes authorized? Auditor to confirm approval. Compliance Assessment Guidance: The auditor shall review the documents for any unauthorized changes. 6.3.8 Are eddy current inspections appropriately performed on 100% of the material/parts or is a sampling plan utilized? Select the correct plan(s). 100% ______ 6.3.8.1 Sampling Plans _______ YES NO N/A YES NO YES NO N/A YES NO N/A YES NO YES NO N/A YES NO

6.3.6 6.3.7

YES NO YES NO N/A

If sampling plans are utilized, have they been approved by the customer? Compliance Assessment Guidance: Auditor to confirm approval.

6.4

Inspection Process Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation.

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AC7114/5

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6.4.1

Do applicable Work Orders/Shop Travelers and Technique Cards contain or provide traceability to the following as a minimum? 6.4.1.1 6.4.1.2 6.4.1.3 6.4.1.4 Part number / Material Identification? Specification reference? Inspection acceptance requirements? Correct sequence of operations? YES NO YES NO YES NO YES NO

6.5

Eddy Current Inspection Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.5.1 Did the inspector review the applicable specification(s), technique sheet, and/or procedure(s) prior to inspecting the material/part? Was the material or part(s) checked for a residual magnetic field prior to the inspection? And if so, were they demagnetized if required? If ferromagnetic material or parts were inspected, was the reference standard, material or part properly demagnetized prior to inspection to ensure that a magnetic field of 2 gauss or less was present when tested with a residual field indicator (magnetometer)? Does the eddy current equipment support the frequency ranges of the probes being used? Is the equipment capable of detecting all relevant discontinuities called out by the customers acceptance specifications? Do the eddy current probe(s) meet the requirements called out by the customer? YES NO

6.5.2

YES NO N/A

6.5.3

YES NO N/A

6.5.4

YES NO

6.5.5

YES NO

6.5.6

YES NO

6.5.7

Were all parts clean? Compliance Assessment Guidance: Parts shall be cleaned in accordance with specific technique instructions. The auditor shall confirm the cleanliness of the parts prior to inspection by whatever means are available and reasonable.

YES NO

6.5.8

Were the parts inspected in accordance with the applicable procedure and/or technique sheet? Compliance Assessment Guidance: The auditor shall confirm these issues by researching the appropriate customer specifications and documentation.

YES NO

6.5.9

Was care taken to ensure that no adjustments were made to the equipment after standardization was completed that could affect inspection performance?

YES NO

6.6

Eddy Current Bearing Inspection Compliance Assessment Guidance: If Bearing Inspection is carried out, answer the following questions under Sub-section 6.6. If bearing inspection is not performed, answer N/A to this sub-section.

N/A

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6.6.1 6.6.2 6.6.3

Were residual field strength measurements taken prior to inspection? If required, were all parts demagnetized prior to performing inspection? If ferromagnetic material or parts were inspected, was the reference standard, material or part properly demagnetized prior to inspection to ensure that a magnetic field of 0.5 gauss or less was present when tested with a residual field indicator (magnetometer)? Is eddy current inspection performed on finished bearing components only? Compliance Assessment Guidance: Finish here is referring to finished parts, not part surface finish.

YES NO YES NO N/A YES NO N/A

6.6.4

YES NO

6.6.5 6.6.6

Was the scanning increment used as defined by the technique/procedures? Was the speed of the inspection the same as that used during the set-up of the equipment? Were all equipment settings made during set-up left unchanged during the inspection? If it was determined that there was an equipment malfunction, was the equipment repaired or replaced and the entire lot re-inspected? Compliance Assessment Guidance: This shall be defined in the suppliers procedure.

YES NO YES NO

6.6.7

YES NO

6.6.8

YES NO N/A

6.6.9

If it was determined that there was residual magnetism present, was/were the rejected material/part(s) demagnetized and re-inspected? Compliance Assessment Guidance: This shall be defined in the suppliers procedure.

YES NO N/A

6.6.10

If it was determined that the set-up or inspection steps were performed improperly, was the entire lot re-inspected following the appropriate corrective action? Following the inspection of a lot of bearing components, was the reference standard re-run for verification purposes? For repeatability, was the signal amplitude response obtained as defined by the technique/procedures? 6.6.12.1 If not, was appropriate corrective action taken to ensure that the inspection was performed properly and that the lot was re-inspected?

YES NO N/A

6.6.11

YES NO

6.6.12

YES NO

YES NO N/A

6.6.13

Is the reference standard representative of the bearing configuration being inspected, per technique/procedure? Compliance Assessment Guidance: Material, inner ring verses outer ring, spherical raceway verses flat, size, etc.

YES NO

6.6.14 6.7

Was the system checked if the inspection ran for more than four hours?

YES NO N/A

Evaluation Compliance Assessment Guidance: The following evaluation process shall be determined by

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AC7114/5
direct observation, and by researching the specifications, procedures and other customer documents that are applicable and required to reach an educated answer to each question. 6.7.1 If required, did the inspector properly evaluate every indication and reject parts containing relevant indications that exceeded the acceptance limits? Were all rejectable indications marked on the part and/or appropriately documented? Was all pertinent paperwork traceable to the part? Were the specific accept/reject criteria properly understood by the inspector? Compliance Assessment Guidance: The auditor is expected to confirm understanding by whatever means are required. This may be possible by observation or, in some cases, may require the auditor to ask the inspector(s) questions regarding the criteria and how it is to be used. 6.7.5 Did the accept/reject criteria properly reflect the customer criteria? Compliance Assessment Guidance: This will be confirmed by the auditor by reviewing the customer P.O and End User drawing if available. 6.7.6 Are all records maintained in accordance with customers requirements? Compliance Assessment Guidance: As a minimum the records shall contain the part #, date, work order, quantity accepted and rejected, serial # (if applicable), reference standard, procedure/technique with revision, inspection facility and inspector.

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YES NO N/A

6.7.2 6.7.3 6.7.4

YES NO N/A YES NO YES NO

YES NO

YES NO

6.8

Post Cleaning & Preservation Compliance Assessment Guidance: The auditor shall verify compliance to this requirement by direct observation. 6.8.1 If required was an adequate post process cleaning operation performed? 6.8.2 After inspection and appropriate cleaning, were parts properly protected from corrosion or damage?

YES NO N/A YES NO N/A

6.9

Inspector Qualification 6.9.1 Were the inspection personnel certified to the correct levels for the work they were performing? Compliance Assessment Guidance: This shall be verified by review of the certification records. 6.9.2 Were all non-certified or in-training personnel observed performing ET operations properly supervised? Compliance Assessment Guidance: This shall be determined by direct observation.

YES NO

YES NO N/A

6.10

Inspection Status 6.10.1 Are symbols and/or marking methods used to denote Eddy Current inspection status? 6.10.2 Were all inspection results properly recorded and traceable to the parts?

YES NO N/A

YES NO