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AC7101/1 REV.

F
Issued 1993-05
AUDIT CRITERIA
Revised 2014-06
161Thorn Hill Road
Warrendale, PA 15086-7527 Superseding AC7101/1 REV. E
TO BE USED ON AUDITS STARTING ON OR AFTER SEPTEMBER 14, 2014

Nadcap
AUDIT CRITERIA FOR MATERIALS TESTING LABORATORIES
GENERAL REQUIREMENTS FOR ALL LABORATORIES
Editorial Changes made to 2.1 on May 12, 2015
K

1. SCOPE

This Audit Criteria was developed by the Nadcap Materials Testing Laboratories Task Group
(MTLTG) for the evaluation of testing facilities for Nadcap Materials Testing Laboratories
Accreditation Program. While the criteria in this checklist may appear redundant with
ISO/IEC 17025/AS9100 audit criteria, the Task Group determined that its aerospace auditors
needed to assess compliance from the aerospace perspective. This Audit Criteria is
applicable to all laboratories. Supplemental checklists provide additional detailed criteriaon
the specific test methods. Appendix A of this document is required for all laboratories
accredited to AS/EN/JISQ 9100 in lieu of ISO/IEC 17025, or AC7006.

The MTL Aduit Handbook provides many details to ensure a successful auidt experience.
The Handbook should be used as a companion to the Audit Criteria. The Handbook is
located on www.eAuditNet.com under Resources → Documents → Public Documents →
Materials Testing Laboratories → Audit Information.

Written customer requirements always take precedence over Nadcap audit criteria.

This section is for the use of auditors, as necessary, for notes during the audit. No NCRs will
be written against section 1.

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 2014 Performance Review Institute. All rights reserved.
t-frm-15 10-Apr-2014
PRI AC7101/1 Revision F -2-

1.1 Audit Category

Initial

Full Scope – Reaccreditation

SV1 – Reaccreditation

SV2 – Reaccreditation

Add Scope

Verification

Internal Audit (NUCAP)

1.2 Audit Scope

AC7006

AC7101/1

AC7101/2

AC7101/3

AC7101/4

AC7101/5

AC7101/6

AC7101/7

AC7101/8

AC7101/9

AC7101/11

AC7109/5

AC7110/13

1.3 OPEN / CLOSE Meeting Attendance

2. ACCREDITATION REQUIREMENTS

2.1 The laboratory demonstrates compliance to an acceptable quality YES NO


system as defined in PD 1100.
Nadcap Materials Testing Laboratories recognizes existing quality
systems approvals in the form of ISO/IEC 17025 certifications by an
ILAC Approved source (www.ilac.org).
PRI AC7101/1 Revision F -3-

For captive laboratories, Nadcap Materials Testing Laboratories also


recognizes AS/EN/JIS Q9100 certifications by registrars that are
approved and listed in the IAQG Oasis database (www.iaqg.org/oasis).
Where no recognized quality systems approvals exsist, Nadcap
requires assessment using AC7006 Audit Criteria Equivalent to
ICO/IEC 17025.
Note: AS/EN/JIS Q 9100 accredited captive laboratories must also
meet the requirements of Appendix A.

2.2 The following summaries are complete (format not cause for NCR, only YES NO
content)
•Personnel Summary: A tabular summary of personnel which perform
the accredited test methods. The summary shall include the following
information:
oName and job title
oTest codes
oQualifications (education, training or examinations)
oYears of laboratory testing experience
•Procedure Summary: A tabular summary of procedures used to
perform the accredited test methods. The summary shall include the
following information:
oDescription of test
oTest code or method
oIdentification of procedures used for testing
oCurrent revision of procedures at time of current audit
oRevision of procedures at date of last PRI audit
•IRR/PT Summary: A tabular summary of IRR/PT activity which support
the accredited test methods. The summary shall include the following
information:
oDescription of test
oTest code or method
oName of proficiency testing provider
oReference of the last PT report (for quick retrieval of the report during
audit)
oDate(s) PT was performed
oRequired frequency of PT
oDescription of any outliers
oReference of the last IRR/operators report (for quick retrieval of the
report during audit)
oDate(s) IRR was performed
oRequired frequency of IRR/operators
oDescription of any outliers
oReference of the last IRR/equipment report (for quick retrieval of the
report during audit)
oDate(s) IRR was performed
oRequired frequency of IRR/operators
oDescription of any outliers
PRI AC7101/1 Revision F -4-

2.3 Procedure(s) are used to ensure Nadcap notification in accordance YES NO


with OP 1107: Nadcap will be notified of any changes to the content on
form number t-frm-11 “Notification of change/request for revised
certification”.

2.4 Self-Audit was completed with references which will satisfy all audit YES NO
criteria in all applicable checklists in the current audit scope.

2.5 A minimum of one Observation of Test is performed by the PRI auditor YES NO
for each testing method in the scope of accreditation within the course
of two audits. Each test was performed in accordance with the
applicable procedures and/or test specification.

2.6 A minimum of three job audits were performed by the PRI auditor. YES NO
Job audits met requirements below (any NO answer results in a NCR
for this criterion. Auditor documentation of each “job audit” shall show
assessment of all the requirements):
•Laboratory received and documented customer requirements
•Test requirements are accurately documented in laboratory testing
documentation (routers/travelers/ other ways to communicate testing
requirements to test operators).
•Laboratory performed required testing in accordance with its
procedures and/or customer requirements.
•Certifications and reports document the methods of data unit
conversion, if applicable, and rounding method if not defined by,
referenced by, or different from test specification.

3. FACILITY (GENERAL)

3.1 Environmental conditions in the laboratory are in accordance with test YES NO
technical requirements such as to facilitate correct performance of the
tests and/or calibrations.

3.2 Environmental conditions are monitored, controlled and recorded as YES NO NA


required. Test environment conditions are considered in creating test
method procedures.

3.3 Cleanliness of test area minimizes contamination. YES NO

3.4 Employees demonstrate compliance to applicable safety program. YES NO

3.5 Facility operations affecting specific testing – Procedures ensure YES NO


notification of customers in the event of interruption due to power
outage or equipment failure that has an effect on the test results.
PRI AC7101/1 Revision F -5-

4. QUALITY SYSTEM DOCUMENT (MANUAL)

4.1 Records are available to the customer upon request within three YES NO
working days.

4.2 A procedure is used to control records (technical data and test reports) YES NO
generated by the laboratory in compliance with customer requirements
including record retention policy.

4.3 Records (technical data) are maintained, traceable to each certification, YES NO
such that the laboratory could reproduce the test method or identify
incorrectly tested material.

4.4 Current revisions of test procedures are used. YES NO

4.5 Laboratory management assigns responsibility for the review and YES NO
approval of test results, training and qualification of personnel, and
procedures.

5. QUALITY ASSURANCE FUNCTION (Q.A.)

5.1 The Q.A. function in the laboratory has stop-work/stop-ship authority. YES NO

5.2 The Q.A. function participates in the organization or planning of YES NO


equipment definition and selection.

5.3 The Q.A. function participates in the organization or planning of YES NO


maintenance and calibration of test facilities and equipment.

5.4 The Q.A. function participates in the management (creation, revision, YES NO
implementation, etc.) of test procedures.

5.5 The Q.A. function has authority to require the implementation, YES NO
extension or modification of internal technical documents.

5.6 The Q.A. function oversees training and qualification of personnel. YES NO

5.7 The Q.A. function participates in the organization or planning of YES NO


subcontractor selection and survey.

6. TRAINING AND QUALIFICATION OF PERSONNEL

6.1 Qualification and training of laboratory personnel complies with YES NO


laboratory quality manual and/or procedures, applicable customer
requirements and is documented.

6.2 Qualification of laboratory personnel includes documented periodic YES NO


“observations of test” to assess the employee’s compliance to
procedures used for Nadcap test codes.

6.3 Individual training records and supporting procedures indicate YES NO


participation in inter-operator comparison as defined by the laboratory.
PRI AC7101/1 Revision F -6-

6.4 Operators are trained to recognize proper operation of the equipment. YES NO

6.5 Operators are trained to recognize a properly executed analysis or test, YES NO
to distinguish between valid and invalid test data, and to justify
invalidating data.

6.6 If degreed personnel “or equivalent” are required, definition of YES NO


“equivalent” is documented.

7. EVALUATION, APPROVAL, AND SURVEY OF SUBCONTRACTORS SECTION NA

7.1 Subcontractor evaluation is based on Nadcap accreditation, customer YES NO


qualification list or at least 3 of the following:
•Documentation and initial survey
•100% inspection of product/service
•Sampling inspection of product/service
•Periodic on-site survey by the Q.A. function

7.2 Access to subcontractor facilities is provided to the laboratory for YES NO


quality audits if requested.

7.3 Applicable quality assurance requirements specified in the contract are YES NO
transmitted to subcontractors.

8. PROCEDURE SYSTEM

8.1 Procedures are approved by the customer, when required. YES NO NA

8.2 Procedure(s) are used for calibration of all Measuring and Test YES NO
Equipment (M&TE) used for testing or producing results.

8.3 A procedure is used to review the requirements presented to the YES NO


laboratory, however defined. The procedure addresses:
•how the requirements are assessed
•how the requirements are effectively communicated to the laboratory
•how the laboratory determines if the requirements can be met
Note: For captive labs, this pertains to how the requirements are
directly communicated to the laboratory, and does not include full
traceability through the company to end-customer requirements.

8.4 Procedures are used to ensure use of ASTM E 29 for rounding unless YES NO
the method is otherwise stated in the certificate of test/test report.

8.5 Procedures define methods and test specifications used to perform YES NO NA
data unit conversions.

8.6 Procedures are used to ensure all software programs and equipment YES NO NA
automation are validated prior to use.
PRI AC7101/1 Revision F -7-

8.7 Procedures are used to ensure all software programs and equipment YES NO NA
automation are revision controlled and that the correct revision is used
for testing and data analysis/compilation/reporting.

8.8 Procedures that are used for each test method reference the source of YES NO
the requirement. For example: specific industry standard(test
specification) or customer specification.

8.9 Procedures are sufficiently detailed so that the test can be consistently YES NO
repeated.

8.10 Details required to reproduce non-standard tests are documented and YES NO NA
traceable to the test report/results.

8.11 Procedures are used to ensure technical revisions of standards YES NO


publications (e.g. ASTM, EN, ISO and any other revision controlled
documents used within test method procedures) in the laboratory’s
scope of accreditation are implemented/incorporated within six months
from the date the standard/document is issued. A record of revision
review is maintained which includes date of reference document
revision, date of laboratory incorporation, brief summary of actions
taken to demonstrate the revision review was completed.

9. EQUIPMENT CALIBRATION AND MAINTENANCE

9.1 Calibration

9.1.1 Calibration cycle extension: When calibration cycles are extended, YES NO NA
procedures are used in accordance with NCSL (National Conference of
Standard Laboratories), recommended Practice 1, or other recognized
statistical review process to support the extended time interval. Any
calibration cycle extensions are in accordance with standard methods
or customer requirements.

9.1.2 Calibration: The laboratory uses a calibration schedule with frequencies YES NO
in accordance with manufacturers’ recommendations, Appendix E, or
the individual checklist requirements for all internal and external
calibrations performed on testing equipment. This schedule documents
duration between calibrations (frequency) and responsibility for
calibration (source).
PRI AC7101/1 Revision F -8-

9.1.3 Calibration: Procedures are used during calibration certificate review to YES NO
ensure the following:
•calibration certificates document the name and address of the agency
performing the calibration.
• approved calibration suppliers are used.
•description(s) of equipment and operating range, including the
precision of the instrument, are documented on the calibration
certificate.
• primary standards or equipment are documented on the calibration
certificate and are traceable to a national standard.
• the calibration method is documented on the calibration certificate.
• the date of calibration is documented on the calibration certificate.
• the "as found" and "as left" conditions are documented on the
calibration certificate when the instrument was adjusted or repaired
during the course of calibration.
• the calibration personnel are documented on the calibration
certificate.
• the environmental conditions are documented on the calibration
certificate where required by standard/spec/customer.

9.1.4 Calibration: Calibration status is identified for each test machine or YES NO
associated laboratory equipment requiring calibration.

9.1.5 Calibration: Procedures are used to address the calibration and use of YES NO NA
“employee-owned” Measuring and Test Equipment (M&TE).

9.1.6 Calibrations not performed by the laboratory are performed by an YES NO


ISO17025 accredited source or documented evaluation.

9.2 Maintenance

9.2.1 Maintenance: Procedures are used to ensure planned maintenance of YES NO


measuring equipment is performed to ensure proper functioning and in
order to prevent contamination or deterioration.

9.2.2 Maintenance: Procedures are used to ensure maintenance records YES NO


identify the maintenance plan, maintenance activities to date, any
damage, malfunction, modification, adjustment or repair to the
equipment.

9.2.3 Maintenance: Procedures are used to identify equipment which is out of YES NO
service.

9.2.4 Maintenance: When maintenance is performed to address a YES NO


malfunction of calibrated equipment, procedures are used to assess the
possible effect on test values.
PRI AC7101/1 Revision F -9-

10. SPECIMEN IDENTIFICATION AND TRACKING SYSTEM

10.1 Unique identification is assigned to each test specimen in accordance YES NO


with a procedure. The identification is retained throughout the life of
the test specimen and is traceable to the final documentation.

10.2 Transfer of work outside the laboratory for sub-contracted processes is YES NO
performed in accordance with procedures which ensure (1) traceability
of documents/records with test articles is maintained and (2) verification
that work performed was in accordance with purchase order
requirements.

11. REPLACEMENT TESTING AND RE-TESTING

11.1 Procedures are used to ensure RETESTS allowed by material or YES NO


customer specification, are performed in accordance with the material
or customer specification.

11.1.1 Unless otherwise specified, procedures are used to ensure a minimum YES NO
of three RETESTS per NON-CONFORMING TEST-RESULT are
performed and reported.

11.2 Procedures are used to ensure replaced tests are recorded and cross- YES NO
referenced with the original tests, including explanations where
applicable.

11.3 Procedures are used to ensure records of replaced tests are reviewed YES NO
periodically for trends which could indicate test process deterioration.
Procedure(s) are used to respond to defined criteria for test process
deterioration which requires corrective action.

12. ERRORS IN TESTING

12.1 Procedures are used to ensure errors in testing are assessed. The YES NO
laboratory reports errors in testing in accordance with the time period
that is required by the customer.

13. CERTIFICATE OF TEST/CERTIFICATE OF CONFORMANCE/TEST REPORTS

13.1 The certificate of test/test report meets the requirements of the YES NO NA
applicable specification.

13.2 The certificate of test/test report includes the name and address of the YES NO
laboratory, and the location where the tests and/or calibrations were
executed, if different from the address of the laboratory.

13.3 The certificate of test/test report includes the name and address of the YES NO NA
customer.
PRI AC7101/1 Revision F - 10 -

13.4 The certificate of test/test report includes identification of the test article YES NO
and identification and issue(s)/revision(s) of the material specification(s)
used for conformance disposition. (Example: Inco 718, AMS5662 Rev
H).

13.5 The certificate of test/test report identifies the testing specification or YES NO
procedure used, if not called out by the material specification. Any non-
standard practices must be documented.

13.6 The certificate of test/test report includes the numerical results of all YES NO
tests and inspections performed for which the material specification
establishes numerical requirements.

13.7 Test values on the certificate of test/test report are recorded, at a YES NO
minimum, to the number of digits as defined by the controlling
specification(s).

13.8 The certificate of test/test report includes descriptions of the results YES NO NA
(e.g., conform/non-conform) of all tests for which the material
specification does not establish numerical requirements.

13.9 Any unusual observations are noted on the certificate of test/test report YES NO NA
(and identified as such, e.g. as “Observation”). Applicable at laboratory
discretion.

13.10 Test results for all specimens in the same set are included on the same YES NO
certificate of test/test report; that is, separate certificates of test/test
reports are not issued for conforming versus nonconforming material.

13.11 The certificate of test/test report includes appropriate description of test YES NO
specimens (quantity, form, and condition, etc), when applicable, and all
identification necessary to assure traceability of laboratory report to the
material supplier/customer records (e.g., sample number, heat number,
lot number, P.O. number).

13.12 The certificate of test/test report includes a statement that it shall not be YES NO
reproduced except in full without the written approval of the laboratory.

13.13 The certificate of test/test report includes each page numbered "page YES NO
__ of__ ".

13.14 The certificate of test/test report includes unique identification traceable YES NO
to the laboratory identification system.

13.15 The certificate of test/test report includes, when applicable, appropriate YES NO
error corrections and revision indication. Manual corrections are
prohibited. Digital documents must have a means for recording
corrections such that the original and corrected data can be observed
during an audit.
PRI AC7101/1 Revision F - 11 -

13.16 The certificate of test/test report includes re-test values, and values YES NO
known to be nonconforming (i.e., when compared against mandatory
specification values), and they shall be clearly identified as such.

13.17 The certificate of test/test report includes documentation of all test YES NO
articles provided to the laboratoryfor testing. Example of test without
results: "Specimen 4A253: No Test - broke in grips”. Test values from
replaced specimens need not be reported.

13.18 The certificate of test/test report is traceable to the request to perform YES NO
work.

13.19 The certificate of test/test report includes a statement of work with YES NO
conformance requirements stated. If the conformance requirements
are written in the statement of work (rather than a specification or
similar document) and revised after submission to the laboratory,
revision to those requirements is documented in the certificate.

13.20 The certificate of test/test reports includes description(s) of any YES NO


applicable thermal treatments performed by the laboratory.

13.21 Computer generated certificates of test/test reports require either (a) an YES NO
actual or facsimile signature, or (b) a letter accompanying the
certificate, signed by the laboratory's representative attesting that the
laboratory is using a computerized system, the typed name on the
document is an authorized employee, and the laboratory is responsible
for the information it contains. If a laboratory uses computer-generated
certificates with an actual or facsimile signature, or typed name, the
system has security (password or other identity control) to ensure the
name on the document represents the individual who performed the
indicated function.

13.22 The certificate of test/test report documents a statement of YES NO


conformance when testing is performed for conformance to material
specifications.

13.23 Procedures are used to ensure correct transcription of data from the YES NO
original source to the certificate of test/test report. Procedure(s) are
used to respond to transcription errors.

13.24 Procedures are used to address revision of certificates of test/test YES NO


reports and notification of customers when errors are found. Customers
are notified within the time period that is required by the customer.

14. PROFICIENCY TESTING AND INTERNAL ROUND ROBIN REQUIREMENTS

Participation in proficiency testing (PT) and internal round robins (IRR)


is required. Frequency requirements are given in Appendix B.
Selection of proficiency test providers is described in Appendix C.
Testing protocol for PT and IRR is described in Appendix D.

14.1 Internal Round Robin Testing


PRI AC7101/1 Revision F - 12 -

14.1.1 The internal round robin program meets the established requirements YES NO
as described in Appendix D.

14.1.2 Internal round robin programs are in place to compare testing YES NO NA
equipment used for the same test/method, if required. (see Appendix B
for frequency and requirements)

14.1.3 Internal round robin programs are in place to compare testing YES NO NA
personnel performing the same test/method, if required. (see Appendix
B for frequency and requirements)

14.1.4 Participation in the internal round robin program meets the frequency YES NO
requirements for all test codes held by the laboratory as described in
AC7101/1 Appendix B.

14.1.5 Procedures are used to ensure participation in Internal Round Robin YES NO
Programs and analyze the results of internal round robins against
defined acceptance criteria.

14.2 Proficiency Testing

14.2.1 Procedures ensure participation in Proficiency Testing Program(s) YES NO

14.2.2 The laboratory used a Proficiency Testing provider in accordance with YES NO
Appendix C.

14.2.3 The participation of the laboratory in Proficiency Testing Program(s) is YES NO


documented.

14.2.4 Participation in the Proficiency Testing meets the frequency YES NO


requirements for all test codes held by the laboratory (see Table 1 of
Appendix B).

14.2.5 The requirements in Appendix D were followed. YES NO

14.3 Statistical Analysis

14.3.1 Statistical analysis and correlation of the data are performed and YES NO
documented for both internal round robin testing and proficiency
testing, if applicable. It is the host facility’s duty to provide a statistical
evaluation of the data in the final report, if applicable.

14.3.2 Procedure(s) are used for investigation of outliers. YES NO


PRI AC7101/1 Revision F - 13 -

A. APPENDIX A

ADDITIONAL QUESTIONS FOR CAPTIVE LABORATORIES CERTIFIED TO AS/EN/JISQ


9100 IN LIEU OF ISO/IEC 17025

A.1 QUALITY SYSTEM DOCUMENT

A.1.1 Quality System Document: If the laboratory is part of an organization YES NO


performing activities other than testing and/or calibration, the
responsibilities of key personnel in the organization that have an
involvement or influence on the testing and/or calibration activities of
the laboratory shall be defined in order to identify potential conflicts of
interest.

A.1.2 Quality System Document: The laboratory has arrangements to ensure YES NO
that its management and personnel are free from any undue internal
and external commercial, financial, and other pressures and influences
that may adversely affect the quality of their work.

A.1.3 Quality System Document: The laboratory has policies and procedures YES NO
to avoid involvement in any activities that would diminish confidence in
its competence, impartiality, judgment or operational integrity.

A.1.4 Quality System Document: Written policy addressing errors in testing is YES NO
established through the Quality Systems Documentation.

A.1.5 Quality System Document: Procedures define the responsibility for YES NO
review and approval of test results, authorization of re-testing, and
preparation or approval of test procedures.

A.2 UNCERTAINTY

A.2.1 Estimation of Uncertainty of Measurement: A calibration laboratory, or a YES NO


testing laboratory performing its own calibrations, shall have and shall
apply a procedure to estimate the uncertainty of measurement for all
calibrations.

A.2.2 Estimation of Uncertainty of Measurement: For non-standard tests, or YES NO


those tests developed by the laboratory for which there is no published
method, the Estimated Uncertainty for the test shall be determined for
any test whose frequency is ten times or more in a six month period,
and to which the requirements of the appropriate AC 7101 checklist
apply. In certain cases, the nature of the test method may preclude
rigorous, metrologically and statistically valid, calculation of uncertainty
of measurement. In these cases, the laboratory shall at least attempt
to identify all the components of uncertainty and make a reasonable
estimation, and shall ensure that the form of reporting of the result does
not give a wrong impression of the uncertainty. Reasonable estimation
shall be based on knowledge of the performance of the method and on
the measurement scope and shall make use of, for example, previous
experience and validation data.

A.2.3 Estimation of Uncertainty of Measurement: When estimating the YES NO


PRI AC7101/1 Revision F - 14 -

uncertainty of measurement, all uncertainty components which are of


importance in the given situation shall be taken into account using
appropriate methods of analysis.

A.3 UNAUTHORIZED PERSONNEL

A.3.1 The laboratory is secure from unauthorized personnel. Access to and YES NO
use of areas affecting the quality of tests and/or calibrations shall be
controlled. The laboratory shall determine the extent of control based
on its particular circumstances.

A.4 SELECTION OF METHODS

A.4.1 Selection of Methods: For sampling, which meet the needs of the YES NO
customer and which are appropriate for the tests and/or calibrations it
undertakes. Methods published in international, regional, or national
standards shall preferably be used. The laboratory shall ensure that it
uses the latest valid edition of a standard unless it is not appropriate or
possible to do so. When necessary, the standard shall be
supplemented with additional details to ensure consistent application.

A.4.2 Selection of Methods: When the customer does not specify the method YES NO
to be used, the laboratory shall select appropriate methods that have
been published either in international, regional, or national standards,
or by reputable technical organizations, or in relevant scientific texts or
journals, or as specified by the manufacturer of the equipment.
Laboratory-developed methods or methods adopted by the laboratory
may also be used if they are appropriate for the intended use and if
they are validated. The customer shall be informed as to the method
chosen. The laboratory shall confirm that it can properly operate
standard methods before introducing the tests and calibrations. If the
standard method changes, the confirmation shall be repeated.

A.4.3 Selection of Methods: The laboratory shall inform the customer when YES NO
the method proposed by the customer is considered inappropriate or
out of date.

A.5 TEST REPORTS

A.5.1 Test reports include where appropriate and necessary for the YES NO
interpretation of the test reults, opinions and interpretations.

A.6 RECORDS

A.6.1 Procedures are used to control and secure records. YES NO

A.7 CONTROL OF TEST MATERIALS

A.7.1 Procedures are used to control all test materials from the point of YES NO
entering the laboratory through the final disposition.

A.8 ERRORS IN TESTING

A.8.1 Errors in Testing: Specific responsibility (individual or title) for YES NO


PRI AC7101/1 Revision F - 15 -

notification of affected customers is documented.

A.9 CALIBRATION

A.9.1 Applicable to non-ISO17025 calibration source: Procedures are used to YES NO


ensure standards are calibrated compliant to ISO17025 and
segregated and controlled to prevent use for anything other than
calibration.

A.10 PROCEDURES

A.10.1 Procedures are used to ensure correct versions of the test procedures YES NO
are used at the time of testing and obsolete procedures/documents are
unavailable for use in testing.

A.10.2 Procedures are used for issue, change management, review and YES NO
approval of documents/procedures issued to personnel. Personnel
authorized for this activity are documented such that names and roles
and responsibilities are clear.
PRI AC7101/1 Revision F - 16 -

B. APPENDIX B

PROFICIENCY TESTING AND INTERNAL ROUND ROBIN REQUIREMENTS

TABLE 1 – FREQUENCIES FOR PROFICIENCY/ROUND ROBIN TESTING PROGRAMS


Note: PT and IRR requirements are listed here by checklist. Some checklists do not have
PT/IRR requirements.

B.1
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/2 – Chemical Analysis
1
D Wet Chemistry Every 2 Years
F Atomic Emission Spectroscopy
1
F1 Direct Current plasma (DCP) Every 2 Years
1
F2 Inductively Coupled Plasma (ICP) Every 2 Years
1
F3 Spark/Arc (OES) Every 2 Years
1
F4 Glow Discharge (GD) Every 2 Years
1
F5 High Temperature Hollow Cathode Every 2 Years
G Combustion or Fusion
1
G1 Carbon Every 2 Years
1
G2 Hydrogen Every 2 Years
1
G3 Nitrogen Every 2 Years
1
G4 Oxygen Every 2 Years
1
G5 Sulfur Every 2 Years
1
S X-Ray Fluorescence (XRF) Every 2 Years
1
V Mass Spectroscopy Every 2 Years

W Atomic Absorption
1
W1 Flame (AAS) Every 2 Years
1
W2 Graphite Furnace (GFAA) Every 2 Years
Notes for Chemistry Analysis IRR/PT Requirements
1
Proficiency testing programs to include all applicable alloy families (Ni, Co, Al, Ti, Fe-High Alloy, Fe-Low Alloy, Cu and
Mg) within 6 Years Maximum.
PRI AC7101/1 Revision F - 17 -

B.2
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/2 – Chemical Analysis


1 2 1 2
D Wet Chemistry Every 2 Years , Every 2 Years ,
F Atomic Emission Spectroscopy
1 2 1 2
F1 Direct Current plasma (DCP) Every 2 Years , Every 2 Years ,
Inductively Coupled Plasma 1 2 1 2
F2 Every 2 Years , Every 2 Years ,
(ICP)
1 2 1 2
F3 Spark/Arc (OES) Every 2 Years , Every 2 Years ,
1 2 1 2
F4 Glow Discharge (GD) Every 2 Years , Every 2 Years ,
1 2 1 2
F5 High Temperature Hollow Cathode Every 2 Years , Every 2 Years ,
G Combustion or Fusion
1 2 1 2
G1 Carbon Every 2 Years , Every 2 Years ,
1 2 1 2
G2 Hydrogen Every 2 Years , Every 2 Years ,
1 2 1 2
G3 Nitrogen Every 2 Years , Every 2 Years ,
1 2 1 2
G4 Oxygen Every 2 Years , Every 2 Years ,
1 2 1 2
G5 Sulfur Every 2 Years , Every 2 Years ,
1 2 1 2
S X-Ray Fluorescence (XRF) Every 2 Years , Every 2 Years ,
1 2 1 2
V Mass Spectroscopy Every 2 Years , Every 2 Years ,

W Atomic Absorption
1 2 1 2
W1 Flame (AAS) Every 2 Years , Every 2 Years ,
1 2 1 2
W2 Graphite Furnace (GFAA) Every 2 Years , Every 2 Years ,
Notes for Chemistry Analysis IRR/PT Requirements
1
Internal Round Robin programs to include all applicable alloy families (Ni, Co, Al, Ti, Fe-High Alloy, Fe-Low Alloy, Cu
and Mg) within 6 Years Maximum.
2
IRR shall be performed for either operators or equipment at the specified frequency. Example 1: IRR could be performed
with one equipment and multiple operators every two years and satisfy the requirement. No IRR for equipment would be
required for this example. Example 2: IRR could be performed with one operator and multiple equipments every two years
and satisfy the requirement. No IRR for operators would be required for this example.
B.3
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/3 – Mechanical Testing
A Room Temperature Tensile Every 2 Years
B Elevated Temperature Tensile Every 2 Years
C Stress Rupture Every 2 Years
XA Creep Every 2 Years
CT Compression Testing Not Required
KR Curve (Resistance to Fracture) Testing Not Required
N Impact Testing Not Required
O High Cycle Fatigue Every 5 Years
P Fracture Toughness Every 5 Years
Y Low Cycle Fatigue Every 5 Years
XE Crack Propagation/Crack Growth Testing Every 5 Years
XN Bend Testing Not Required
PRI AC7101/1 Revision F - 18 -

Notes for Mechanical Testing IRR/PT Requirements – No Notes.


B.4
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/3 – Mechanical Testing


A Room Temperature Tensile Every 2 Years Every 2 Years
B Elevated Temperature Tensile Every 2 Years Every 2 Years
C Stress Rupture Every 2 Years Every 2 Years
XA Creep Every 2 Years Every 2 Years
CT Compression Testing Not Required Not Required
KR Curve (Resistance to Fracture) Testing Not Required Not Required
N Impact Testing Not Required Not Required
O High Cycle Fatigue Every 5 Years Every 5 Years
P Fracture Toughness Every 5 Years Every 5 Years
Y Low Cycle Fatigue Every 5 Years Every 5 Years
XE Crack Propagation/Crack Growth Testing Every 5 Years Every 5 Years
XN Bend Testing Not Required Not Required
Notes for Mechanical Testing IRR/PT Requirements
1.If an IRR is performed for Creep, then Stress rupture IRR is not required.
2.Suppliers are allowed to propose an IRR/PTP test plan for task group approval. Plan may include SPC and/or Gage
R&R data/analyses.

B.5
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/4 – Metallography and Microindentation Hardness
L General Metallography Not required
Grain Size Measurement Every 2 Years
Inclusion Rating Not Required
L1 Microindentation Hardness Every 2 Years
L2 Alloy Depletion Not Required
L3 Oxidation/Corrosion Layers Not Required
L4 Casting (Mold) Reactions Not Required
L5 Microindentation (Surface-case depth) Every 2 Years
L5X Microindentation (Surface) (ARP1820) Not Required
L6 Nitriding Not Required
L7 IGA / IGO Not Required
L8 Alpha Case: Wrought L8 or L9 Every 2 years
L9 Alpha Case: Castings L8 or L9 Every 2 years
L10 Carburization/Decarburization Not Required
LS Near-Surface Examinations Not Required
XL Macro Examination Not Required
Notes for Metallography and Microindentation Hardness IRR/PT Requirements – No Notes.
PRI AC7101/1 Revision F - 19 -

B.6
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/4 – Metallography and Microindentation Hardness


L General Metallography Not required Not required
Grain Size Measurement Every 2 Years Not Required
Inclusion Rating Every 2 Years Not Required
L1 Microindentation Hardness Every 2 Years Not Required
L2 Alloy Depletion Every 2 Years Not Required
L3 Oxidation/Corrosion Layers Every 2 Years Not Required
L4 Casting (Mold) Reactions Every 2 Years Not Required
L5 Microindentation (Surface-case depth) Every 2 Years Not Required
L5X Microindentation (Surface) (ARP1820) Every 2 Years Not Required
L6 Nitriding Every 2 Years Not Required
L7 IGA / IGO Every 2 Years Not Required
L8 or L9
L8 Alpha Case: Wrought Not Required
Every 2 Years
L8 or L9
L9 Alpha Case: Castings Not Required
Every 2 Years
L10 Carburization/Decarburization Every 2 Years Not Required
LS Near-Surface Examinations Every 2 Years Not Required
XL Macro Examination Every 2 Years Not Required
Notes for Metallography and Microindentation Hardness IRR/PT Requirements – No Notes.

B.7
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/5 – Hardness (Macro)
M1 Hardness (Brinell) Every 2 Years
M2 Hardness (Rockwell) Every 2 Years
M3 Hardness (Vickers) Every 2 Years
Notes for Hardness IRR/PT Requirements – No Notes.

B.8
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/5 – Hardness (Macro)


M1 Hardness (Brinell) Every 2 Years Every 2 Years
M2 Hardness (Rockwell) Every 2 Years Every 2 Years
M3 Hardness (Vickers) Every 2 Years Every 2 Years
Notes for Hardness IRR/PT Requirements – No Notes.

AC7101/6 – Corrosion: No PT/IRR Requirements


B.9
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/7 – Mechanical Testing Specimen Preparation
Z2 Low Stress Grinding and Polishing Every 2 Years
Notes for Mechanical Testing Specimen Preparation IRR/PT Requirements – No Notes.
PRI AC7101/1 Revision F - 20 -

B.10
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/7 – Mechanical Testing Specimen Preparation


Z2 Low Stress Grinding and Polishing Every 2 Years Every 2 Years
Notes for Mechanical Testing Specimen Preparation IRR/PT Requirements – No Notes.

AC7101/8 – Differential Thermal Analysis: No PT/IRR Requirements

AC7101/9 – Test Specimen Response/Capability to Heat Treat: No PT/IRR Requirements

AC7101/11 – Fastener Testing


B.11
CODE TEST TYPE Proficiency Testing Frequency Date Performed
AC7101/11 – Fastener Testing
15 Torque – Tension Not Required
31 Torque – Locking, Torque-Out Not Required
40L2 Metallography – Alloy Depletion Not Required
40L3 Metallography – Oxidation / Corrosion Not Required
40L7 Metallography – IGA / IGO Not Required
40L8 Metallography –Alpha Case: Wrought Titanium Every 2 Years
Metallography – Decarburization /
40L10 Not Required
Carburization
40L25 Metallography – Grain Size Every 2 Years
6-M2 Hardness – Rockwell Every 2 Years
6-M3 Hardness – Vickers Every 2 Years
6-L5 Hardness – Microindentation Hardness Every 2 Years
8-P Tensile Test – Proof Load (nuts / screws) Not Required
8-A Tensile Test – Axial Tensile Every 2 Years **
8-W Tensile Test – Wedge Tensile Every 2 Years **
18 Tensile Test – Elevated TempTensile Every 2 Years **
10 Stress Rupture Every 2 Years *
11 Fatigue Every 5 Years
13 Shear Strength – Double Shear Every 2 Years
5 Stress Durability – External Threads Not Required
14 Stress Durability – Internal Threads Not Required
Q Corrosion – Salt Spray Not Required
QF Corrosion – Copper Sulfate Not Required
Notes for Fastener Testing IRR/PT Requirements
1. See also AC7101/11 Table 1 regarding assignment of test codes
2. Any of the above PT or IRR requirements, if not fastener specific, can be met through other accredited checklists (does
not apply to fatigue).
3. * If result of a stress rupture test is to discontinue at a defined point, no PT or IRR is necessary.
4. ** If elevated temp tensile has been performed for PT or IRR (and all operators are the same), equivalent room
temperature participation is not necessary.
5. Only one room temperature tensile PT is required. Separate participation is not required for axial or wedge.
6. If case depth utilized microhardness, separate PT for microhardness is not required.
PRI AC7101/1 Revision F - 21 -

B.12
Internal Round Internal Round
CODE TEST TYPE Robin Frequency Date Performed Robin Frequency Date Performed
for Operators for Equipment

AC7101/11 – Fastener Testing


15 Torque – Tension Every 2 Years Not Required
31 Torque – Locking, Torque-Out Every 2 Years Not Required
40L2 Metallography – Alloy Depletion Not Required Not Required
40L3 Metallography – Oxidation / Corrosion Not Required Not Required
40L7 Metallography – IGA / IGO Not Required Not Required
Metallography –Alpha Case: Wrought
40L8 Every 2 Years Not Required
Titanium
Metallography – Decarburization /
40L10 Not Required Not Required
Carburization
40L25 Metallography – Grain Size Every 2 Years Not Required
6-M2 Hardness – Rockwell Every 2 Years Every 2 Years
6-M3 Hardness – Vickers Every 2 Years Every 2 Years
6-L5 Hardness – Microindentation Hardness Every 2 Years Every 2 Years
8-P Tensile Test – Proof Load (nuts / screws) Not Required Not Required
8-A Tensile Test – Axial Tensile Every 2 Years ** Every 2 Years **
8-W Tensile Test – Wedge Tensile Every 2 Years ** Every 2 Years **
18 Tensile Test – Elevated Temp.Tensile Every 2 Years ** Every 2 Years **
10 Stress Rupture Every 2 Years * Every 2 Years *
11 Fatigue Every 5 Years Not Required
13 Shear Strength – Double Shear Every 2 Years Every 2 Years
5 Stress Durability – External Threads Not Required Not Required
14 Stress Durability – Internal Threads Not Required Not Required
Q Corrosion – Salt Spray Not Required Not Required
QF Corrosion – Copper Sulfate Not Required Not Required
Notes for Fastener Testing IRR/PT Requirements
1. See also AC7101/11 Table 1 regarding assignment of test codes
2. Any of the above PT or IRR requirements, if not fastener specific, can be met through other accredited checklists (does
not apply to fatigue).
3. * If result of a stress rupture test is to discontinue at a defined point, no PT or IRR is necessary.
4. ** If elevated temp tensile has been performed for PT or IRR (and all operators are the same), equivalent room
temperature participation is not necessary
5. Only one room temperature tensile PT is required. Separate participation is not required for axial or wedge.
6. If case depth utilized microhardness, separate PT for microhardness is not required.

AC7109/5 – Coating Evaluation Laboratory Practices: See AC7109/5 for PT/IRR requirements

AC7110/13 – Evaluation of Welds: No PT/IRR requirements


PRI AC7101/1 Revision F - 22 -

C. APPENDIX C

SELECTION OF A PROFICIENCY TEST (PT) PROVIDER

When not practical or feasible to use a provider from the PRI list of recognized providers (found at
www.eAuditNet.com, Resources →Documents →Public Documents →Materials Testing →IPT Information),
three other options are available in this appendix.

Option 1 Using an unrecognized Proficiency Testing provider

The laboratory can participate in PT by other commercial providers if at least 8 of the “Rules
for acceptance of commercial proficiency testing providers” (listed below) are validated by
the provider and verified by the laboratory.

Option 2 How to use a Subscriber Program as a Proficiency Testing Provider

The laboratory can use a Subscriber specific program only after PRI Staff Engineer and
Subscriber concur regarding confidentiality and method validation.

Option 3 Option 3 – Submit a plan to meet the intent of proficiency testing for Task Group approval.
Supplier shall retain an approved plan to meet this requirement.

Laboratories are responsible to ensure the provider they use conforms to the rules of this appendix (listed below)
at time of use.

Rules for acceptance of commercial proficiency testing providers.

The *Full Process Provider, to be recognized by the MTLTG, shall be compliant with Criterion 1 or Criterion
2
*Full Process Provider - A provider that supplies the sample in a condition to require participating testing
laboratory to utilize their entire process (e.g. sample preparation and testing). (Not one that submits
photographic sample for review only.)

Criterion 1: ISO Guide 43 or ILAC G-13 Compliance and 3rd party accreditation (such as ISO 9001, ISO 17025,
and the scope of the accreditation corresponding). OR

Criterion 2: ISO Guide 43 or ILAC G-13 Registration and the following rules.

Rule 1 Materials and tests scope offered by the provider comply with our aeronautic requirements
(Standard used are listed in our referenced documentation).

Rule 2 Homogeneity study of material shall be explained and compliant with Rules 3 and 4:

Rule 3 20 specimens per sheet, tubes or batch is recommended for the homogeneity analyses. Less than
10 specimens per sheet, tubes or batch analyses will not be accepted.

Rule 4 Risk analyses to exclude a participant because of an inhomogeneous material shall be less than
5%.

Rule 5 The number of participants per test program shall be more than 30 to have a robust statistical
analyse (less than 10 not accepted (per ASTME2489)).

Rule 6 Time process between the beginning and the end of the program shall be less than 6 Months
PRI AC7101/1 Revision F - 23 -

(Root cause analyses concern).

Rule 7 Time process between the final reporting of results and the data analysis report shall be less than
3 months (Root cause analyses concern).

Rule 8 Numbers of specimens per test (sufficient number of specimens to ensure repeatability).

Rule 9 Statistical analyses performed (repeatability, median & sigma or k studies).

Rule 10 Interpretability of the report shall be easy and without waste off time for the auditor (the raw data
record the method used shall clearly appear).
PRI AC7101/1 Revision F - 24 -

D. APPENDIX D

D.1 SPECIFIC TESTING PROTOCOL FOR INTERNAL ROUND ROBINS

(A) Membership – A coordinator of the Internal Round Robin program shall be assigned. It is
the coordinator’s responsibility to design the test method protocol, distribute testing
materials, guide the testing phase, and construct a final report based on the data obtained.

(B) Participants – Participants are qualified operators or candidates for qualification. It may
be one operator using various equipment or procedures to perform the same test method
(e.g. comparing results from three different Rockwell hardness testers). It may also be
several qualified operators using the same equipment and operating procedures to produce
test results.

(C) Quantity of Test Results (Replicates) per test method – The minimum number of
replicates per operator or equipment will normally be two to estimate repeatability. Three or
four replicates per operator or equipment is desirable for chemical, mechanical and optical
tests depending on time as well as cost factors associated with the test method. The
laboratory procedure shall define the minimum quantity of tests to be conducted and also
establish criteria for increasing the number of replicates per operator or equipment.

(D) IRR testing protocol is in accordance with general testing protocol for IRR and PT below

D.2 GENERAL TESTING PROTOCOL FOR INTERNAL ROUND ROBINS (IRR) AND
PROFICIENCY TESTING (PT)

(A) Basic Design – The testing protocol should be designed such that the results obtained
from the chosen method can be classified easily to study the within – and between – facility
variability without the influence of secondary effects.

(B) Within facility variability, referred to as repeatability, concerns the variability between
independent testing results obtained within a single facility in the shortest practical period of
time by a single operator with a specific set of test apparatus using test specimens taken at
random from a single quantity of homogeneous material obtained or prepared for the study.
The single operator – single set of apparatus requirement means that given a particular step
in the measurement process, the same combination of operator and apparatus is used for
every test result (replicate) and on every material. Thus, one operator may prepare the test
specimens, a second operator measure the dimensions and a third operator may perform the
test.

(C) Timing Precision - “Shortest practical period of time” means that the test results, at least
for one material, are obtained in a time not less than in normal testing and not so long as to
permit significant changes in the test material, equipment or environment.

(D) Between facility variability, referred to as Reproducibility, deals with the variability
between single test results obtained in different facilities, each of which has applied the test
method to the test specimens taken at random from a single quantity of homogeneous
material obtained or prepared for the study.
PRI AC7101/1 Revision F - 25 -

(E) Data Classification – One form of classification suggested is a separate matrix table for
each property tested, in which the rows represent the facilities and the columns represent
the materials (or vice versa). Each cell, the intersection of a row with a column, contains the
test results made by a particular laboratory for a particular material. (For practicality reasons
regarding certain test methods, the terms material and property may be interchanged in this
paragraph).

(F) Test Method – The actual measurement process and the written description of the
process. A written draft of the test method shall be constructed that describes the test
procedure, identifies test conditions affecting the test results, and specifies the proper
degree of control of the test. The number of significant digits to be reported shall also be
designated and shall follow, as a minimum. The test method shall include any special
calibration procedure and the frequency of calibration required, if applicable.

(G) Global Instruction - The name, address, e-mail address, telephone and fax number of the
key person(s) coordinating and supervising the proficiency testing should be provided in the
protocol. The participating laboratories shall be instructed to contact the coordinator when
any questions arise as to the conduct of the proficiency testing.

(H) Test Identification – Clearly identify the test method, specifying any option(s) in
apparatus or procedure selected. Test units and test data sheets should be given for each
option.

(I) Material Consistency - Each material selected shall be supplied by one source and made
to be as homogeneous as possible, prior to its subdivision into test specimens. The location
of every test specimen from the bulk material shall be traceable through a letter and/or
number designation indicated on each sample. In other words, a log or schematic of the
location referencing where each test specimen originated from the bulk material shall be
maintained. The samples shall be randomized before distribution and a record shall be
maintained of which facilities (EPT) or operators and equipment (IRR) are testing which
sample number(s).

(J) Calibration Procedures – Calibration procedures required before every test result should
be described in detail in the test method, if applicable.

(K) Specific Conditions Analyses – Characterize any special circumstances that must be
addressed in executing the repeatability conditions (e.g. the length of time between obtaining
the test results for the same material).

(L) Handling and Conditioning – Stipulate the required care, handling and conditioning of the
material(s) to be tested, if applicable. Describe the coding system used to identify the
material(s) to be tested.

(M) Host Facility Data Collection – The host laboratory or provider may provide data sheets
for recording the raw data as observed. Supply sheets on which test results can be
calculated or combined with the raw data sheet(s), if applicable. Request that all raw data
be sent as soon as the testing is completed, or at regular intervals for testing which extends
over several weeks.
PRI AC7101/1 Revision F - 26 -

(N) Data sheets should be provided so that each laboratory can record any special events
that arise during any phase of the testing. In addition to a ‘comments’ section, questions
pertinent to the test method may be asked to get a better idea of how the test was carried out
as long as the information is not proprietary. Any information that would ensure that the
laboratory complied with the requirements specified for the test method or that may be
needed to prepare for the final report should also be requested. The recorded comments will
serve as a valuable source of information both in handling outlying data and for improving
the test method for future proficiency testing. Obtain suggestions for future testing regarding
the test method and test materials.

(O) Replacement – The protocol must contain information about the availability of the
material(s) for replacement tests. It is recommended that the host laboratory prepare
enough of each material to supply 50% more than needed by the number of facilities
committed to the testing program. Instruct the facilities to notify the test coordinator
immediately whenever an error in test procedure occurs. It can then be determined whether
a new set of test specimens needs to be provided for a replacement test of the material(s).

(P) Final Report – A formal report shall be distributed by the host to all participants,
containing a description or summary of the test method, materials and the reported test
results from all participants. Testing sponsored by Nadcap-accredited facilities should
clearly state which Nadcap testing requirement(s) are met (e.g. This testing fulfills Nadcap
requirements for Stress Rupture in January of 2010). Participants shall be identified by code
to minimize the possibility of bias during data analysis. Each participant shall be informed of
its code assigned by the host to maintain confidentiality.
PRI AC7101/1 Revision F - 27 -

E. APPENDIX E

CALIBRATION FREQUENCY (MAXIMUM)

GENERAL EQUIPMENT REQUIRED FREQUENCY

Precision Indicators 3 Months


(e.g., Test Temperature Indicators)

Laboratory Facility Temperature/Humidity 1 Year


Measuring Instruments

Recording Systems: 6 Months


To + 1% of full scale range
(e.g., X-Y Strip Charts)

Precision Potentiometers 3 Months

Micrometers/Verniers 6 Months

Optical Comparator 1 Year

Oscilloscopes 1 Year

Note:Calibration cycles may be extended as defined by the NCSL (National Conference of Standards
Laboratories), Recommended Practice 1, or other recognized statistical review process to support the
extended time interval. Calibration frequencies defined by standard methods or supplier requirements
shall not be extended. Calibration extension shall be allowed only if documented historical data and
standard calibration practices substantiate the extension of calibration frequencies.