mda qsma solutions mr. edward jopson assistant director mda/qsi cqsdi march 27 2007

MDA QSMA Solutions

Mr. Edward JopsonAssistant Director

MDA/QSICQSDI March 27 2007

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MDA PROGRAM CHALLENGES

THTH

Developmental Systems morphs to Operational System – Reliability standards are inherently more stringent

Heritage Programs – Different mindsets, focuses and cultures, integration of these Heritage Programs into a BMDS

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MDA PROGRAM CHALLENGES (CONT’D)

Acquisition Reform - Performance-based specifications and “Best Practices” replacing MIL-STDs

Spiral Development - Qualification baseline changes and lack of test data to validate models

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MDA SAFETY, QUALITY AND MISSION ASSURANCE DIRECTORATE

ROLES AND RESPONSIBILITIES• Develop and maintain within MDA a world-class Safety, Quality and Mission

Assurance (SQMA) organization• Provide BMDS Elements with robust and practical policy, guidance and expertise• Develop an integrated BMDS SQMA team across MDA, the program elements,

and the Ballistic Missile Defense industry• Provide MDA personnel and resources to assist Elements and Industry in SQMA

activities• Terminate any operation that presents an immediate and unacceptable risk to

personnel, property, or mission operations

MDA/QS DESCRIPTION• Started October 2002• Currently encompasses 134 personnel in 28 locations• Supplier facilities, Test sites, Government facilities• Direct Report to MDA Director

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MDA/QS

DirectorQuality, Safety And Mission Assurance (QS)

Assistant DirectorMission Assurance (QSA)

Assistant DirectorSafety (QSS)

Assistant DirectorQuality (QSQ)

Assistant DirectorAssurance Integration (QSI)

QS provides a continuous assessment of the engineering, technology, processes, production and programmatic practices applied to the complex and critical

Ballistic Missile Defense System.

MDA Assurance Provisions (MAP) DCMA Letter of Delegation

MDA Assurance Representatives System/Range Safety

Unfettered Access Parts, Materials and Processes Program

Mission Assurance and Safety Audits Software Acquisition Process Improvement

MDA Assurance Group Test/Operational Safety (BSOs)

MDA Advisory Process Supplier Roadmap

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QS FIELD LOCATIONS MARs, BSOs & SAFETY PERSONNEL

Raytheon, Woburn, MARaytheon, Andover, MA

Lockheed, Sunnyvale, CA

Vandenberg AFB, Lompoc, CA

ABL, Kirtland AFB, NM

Eagle Picher, Joplin, MO

Lockheed, Moorestown, NJ

MDA HQ

Raytheon, Camden, AR

ATK, Elkton, MD

Ft. Greely, AK

Ft. Greely, AK

Kodiak Facility, AK

Raytheon, Tucson, AZ

Orbital, Chandler, AZSpectrum Astro, Gilbert, AZ

ATK, Magna, UT

Honeywell, Clearwater, FL

Aerojet, Sacramento, CA

Lockheed, Denver, CO

KI, Huntsville, ALGMD, Huntsville, ALTHAAD, Huntsville, AL GMD, Huntsville, ALGMD/IM & CTF, Huntsville, AL

JNIC, COBSOs (6)

Northrop Grumman, Redondo Beach, CABoeing, Anaheim, CA

Edwards AFB, CA

Black = QSLBlue = MARGreen = BSORed = Safety

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Mission Assurance (QSA)Safety (QSS) Quality (QSQ)Assurance Integration (QSI)









MDA/QS

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MDA ASSURANCE PROVISIONS (MAP)

• A standardized set of 14 SQMA provisions, requirements, and processes for mission and safety critical items:

- Management- Design and Development- Software and Firmware- Technical and Mission Assurance Reviews- Reliability, Maintainability, and Availability- Parts and Materials Control Program- Integrated Test and Evaluation Program- Test, Measuring and Diagnostic Equipment and Standards- Interface Management- Configuration Management- Control of Nonconforming Items and Materials- Fabrication and Quality- Supplier Management- Safety

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MDA ASSURANCE PROVISIONS (MAP) (CONT’D)

• Provide methods to measure, verify, and validate mission success through:

- Collection and analysis of metrics- Risk Assessment, technical evaluations, independent

assessment, reviews - Conducting tests

• Promote continuous process improvement to reduce cost, improve productivity, and assure SQMA

• Specific applicability is defined in Mission Assurance Implementation Plan (MAIP) – Verification Matrix

MAP is on/almost on all MDA contracts

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Improve Element MA Programs

Formally Incentivize Mission Success

Mandate Use Of “Golden Round” Philosophy – Test Like You Operate

Flow Down MA Requirements To Contractors And Vendors

MDA Assurance Provisions

Evaluate / Understand Element MA Practices

Independent Assessment• QS Personnel Matrixed Throughout MDA Elements• Provide Comprehensive “Second Look”

Matrix QS Personnel Into Elements• Perform Gap Analysis• Collect / Share / Apply Lessons Learned• Prioritize High Risk Items

MAP As A Core Standard On All New Contracts

Build Integrated MA Team Throughout MDA

Near-Term Mid-Term Long-Term

Define / Implement Mission Assurance Program For The BMDS

MDA ASSURANCE PROVISIONS (MAP) COOPERATIVE APPROACH IMPLEMENTATION

Refine And Improve MAP And MDA MA Processes

Perform Independent Reviews

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MISSION ASSURANCE IMPLEMENTATION

Time

IDOFlight

Testing &Verification

Element Integration & Ground Test

Block 06Flight



ManufacturingDesign &

Development

Block 08Flight



ManufacturingDesign &

Development

ManufacturingDesign And Development

Increasing Opportunity For Block 06

Maximum Opportunity For Block 08

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MDA/QS

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MDA ASSURANCE REPRESENTATIVES

MARs provide MDA with deployed Mission Assurance resources for direct and unfiltered supplier insight, with the leverage to effect value added change and mitigate risk in a timely fashion, and serve as MDA’s Mission Assurance ambassadors to its Supplier community, associated agencies and organizations

Responsibilities:

- Rapidly identify, report and resolve technical issues on both hardware and software that impact the safety and reliability of the Missile Defense program

- Immediately report to the supplier’s program office and to MDA/QS any safety concerns/issues

- Immediately report to MDA/QS significant hardware/software issues impacting upcoming missions

- Report and resolve safety, quality, and reliability issues/concerns impacting MDA hardware and software

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• Responsibilities (cont’d):

- Represent QS Directorate and Cognizant Program Office- Provides DCMA and contractor direct access to MDA- Provides MDA Director unfiltered insight into program operations in real-

time- Participates in design integration, test, qualification activities and issue

resolution- Ensures that all applicable safety, quality and mission assurance provisions

are being followed- Disseminates lessons learned to counterparts at all BMDS components and

DCMA- On-site authority for QS LOD to DCMA

MDA ASSURANCE REPRESENTATIVES (CONT’D)

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MAR vs DCMA ROLES

Mission Assurance Quality Adherence

Dedicated MDA Resource (Agency Focus) Matrixed, Non-Dedicated, Contract Focus

MA Ambassador (Leadership & Influence) N/A

Direct Feedback Non-Direct Feedback

Pre-Emptive Role (Initiate Risks) N/A

BMDS Perspective Facility/Product Specific

System & Subsystem Cognizance N/A

System & Subsystem Test Adequacy Test Surveillance

Adequacy Of Requirements Requirement Compliance

Acceptability Of Issue Resolution Surveillance

Adequacy of Quality Process Mandatory Inspections

Adequacy Of Process & Procedure Procedure Adherence

Cross Element Comm/Coord N/A

MARs DCMA

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MDA/QS

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Unfettered Access Direction

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MDA/QS



QS provides a continuous assessment of the engineering, technology, processes, production and programmatic practices applied to the complex and critical Ballistic

Missile Defense System.







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AUDIT PROCESS

• Product Design • Product Requirements• Processes

• SQMA Requirements• MDA/Industry Best-

Practices (MDA Assurance Provisions & Other MIL-STDs/Guidelines)

• Contractor Plans, Procedures, Practices and Records

“Comparison”

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MDA ASSURANCE AUDITS

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MDA ASSURANCE AUDITS

• Validate that end items at a selected level conform to engineering design requirements

• Validate end item at a selected level is qualified

• Compare fabrication methods and acceptance test levels against MDA & industry standards as appropriate for MDA use

• Validate production readiness

• Assess Contractor/Government Mission Assurance practices, procedures, and implementation

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MISSION ASSURANCE AUDIT SCOPE

• Management Systems

• System Design

• Integrated Test and Evaluation

• Supplier Management

• Configuration Management

• Safety

• Reliability, Maintainability, and Availability

• Software

• Parts, Materials, and Processes

• Fabrication and Quality

• Quality Management System – AS9100

• Other Safety, Quality, & Mission Assurance Practices

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MDA/QS

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MDA ASSURANCE GROUP

The MDA Assurance Group (MAG) is used to ensure industry-wide understanding and implementation of the MDA Quality, Mission Assurance and Safety requirements, as set forth by the MDA/QS Director

MAG membership includes key Government and aerospace industry executives knowledgeable of quality enterprise strategic planning, Quality Management System (QMS) requirements / implementation, mission assurance principles, and knowledge of their companies Missile Defense programs

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MDA ASSURANCE GROUP (CONT’D)

• Primary responsibilities of the MAG are to:

- Review and discuss the MDA Quality, Mission Assurance and Safety policies and strategies set forth by the MDA Director to make certain implementation facilitates mission success

- Identify, discuss and resolve significant, cross-cutting systemic issues affecting MDA programs

- Understand the activities of other Aerospace Industry groups/associations like SQIC, AAGQ, AIA, etc with purpose to eliminate redundant activity and to gather their lessons learned

• MAG Meetings were held on 15 March 2005 and 28 February 2006

• Key MAG Members: MDA, NASA, Boeing, Aerojet, Northrop Grumman, Raytheon, Lockheed Martin, ATK

• Ex: Spawned “Stakeholder Initiatives”

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MDA/QS

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MDA ASSURANCE ADVISORIES

• MDA Assurance Advisories (MAA) provide information about problems, potential problems and failure experience data on parts, components, materials, manufacturing processes, specifications, computer software, test equipment and safety

• Advisories are exchanged to improve quality, reliability, and delivery schedules and to reduce costs

• Implemented in October 2003, QS has published 23 Advisories. Distribution to the MDA program elements, Industry, NASA, NRO and SMC

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MDA/QS

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DCMA DELEGATION OF AUTHORITY

• Agreement between the Missile Defense Agency Director and the Defense Contract Management Agency Director…

- Establishes quality oversight requirements for mission critical

items

- Defines MDA expectations and priorities

- Empowers DCMA to provide hands on quality insight/oversight

- Establishes quality assurance insight/oversight requirements

throughout the supply chain

- Provides commonality and consistency for quality assurance

implementation

- Provides a government influence on mission success

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DELEGATION PROVIDES…

• DCMA Quality Assurance oversight requirements for:

- Quality assurance surveillance strategy & plan

- Process surveillance activities

- Contract management offices reporting and notification

- Material review board activities

- Mandatory Government Inspections (MGIs):

Critical lifts and operations

Test setup (i.e., equipment and crew certifications, documentation

verification)

Final inspection

Pre-shipment and shipment activities (i.e., black box closeout,

DD250, etc.)

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MDA/QS

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PARTS, MATERIALS AND PROCESSES PROGRAM

• State of MDA PMP Today- Non-standardized PMP management- COTS Technology and Obsolescence management lacks

definition- MDA lacks a comprehensive product engineering process

• MDA/QS PMP- MDA-wide PMP Management Plan- MDA Parts, Materials and Process Board/Control Boards- MDA Preferred Parts List- Pilot Program developed for GMD Product Lines

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Why the PMAP?

• PMAP meets two of the Director’s goals:

- Support the operations and sustainment of capabilities fielded to the warfighter – Eliminates variability in screening and qualification of

PMP– Improves the probability of mission success– Ensures repeatability in the qualification baseline

- Develop an integrated capability for Block 2006 and beyond– Through a fully integrated Agency PMP program

Uniformity of Requirements Across All ElementsUniformity of Requirements Across All Elements

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Why the PMAP is Necessary…Industry State of Affairs

• Overseas Plants

- Limited processes and material change knowledge- Military parts built on comm. manufacturing lines- Easy access: foreign countries reverse engineer military

technology

• Unauthorized Distributors

- No established relationship with part vendors, poor quality, no recourse – traceability issues

- Inconsistency in vendor lot to lot parameters- Counterfeit fasteners - rivets, nuts, bolts, washers

• Lead-free Initiative

- Pandemic for Hi-Rel systems- No accepted method for tin-whisker mitigation- Government - military and space application

• Obsolete Parts

• EEE parts represent decreasing market share

Commercial Driven Industry = Greater Controls RequiredCommercial Driven Industry = Greater Controls Required

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Why a PMP Program is Necessary… Counterfeit Components

• Unauthorized Manufacturers

- Build fake parts, selling cheap or defective devices at brand name prices

- Buy low-power die for high-power packages

- Parts marked with “high-rel” part no.

- Fabricate parts to substandard processes

• China # 1 Seller

- $1 - 10 billion per year (estimate)

- 35% of world market by 2010

- Fab sites expanding rapidly, little govt control

- Patent infringement

• Companies Counterfeited

- Motorola - On Semi

- Toshiba - National

- PMC-Sierra

Counterfeit Genuine

Counterfeit Genuine

Counterfeit capacitors with substandard electrolyte

Note the difference in part numbers

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PMAP Requirements & Section Highlights

• IntroductionScope - Purpose

• Applicable DocumentsGovernment, Commercial

• PMP Management Structure, Roles, and ResponsibilitiesPMP Control Board

• PMP RequirementsProgram categories and definitionsManagement of PMP selection & Quality RequirementsRequirements Applicability Matrix PMP ProcurementRad Hard, GFE, GFMPMP QualificationNon-Conforming Materials and PartsFailure AnalysisESD Control, Environmental Controls, Handling ControlsPreservation, Packaging and Storage Requirements

• AppendicesDeratingPEMSCOTSRadiation HardnessProhibited Parts & Materials

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MDa Assurance Representatives System/Range Safety





MDA/QS

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• Supplier Roadmap and Supply Chain Database- 453 Suppliers in 39 states and 2 foreign countries

• Can be searched by:- Congressional District- State- Supplier- Program

SUPPLIER ROADMAP

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SUPPLIER ROADMAP (CONT’D)

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Mission Assurance and Safety Audits Govt/Industry Lessons Learned Program



MDA/QS

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“The frustrating part about it is we have not had an incident that, in my view, can be classified as a failure of the technology. . . Someone didn’t perform a process right, somebody left out a piece of material where they shouldn’t. . .” Former MDA Director, Lt Gen Ronald Kadish, December 2003

Roadshow Targets all audiences: Program Offices, President, Vice President, Director, Chief Engineer, Systems Engineering Manager, IPT Leads, Engineers, Quality, Safety and Mission Assurance Personnel and Technicians

Discusses Lessons Learned on IFT-13c and IFT-14 Tests

MDA LESSONS LEARNED ROADSHOW

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Test Root Cause Fundamental Issue

Test 2

Countdown automatically aborted due to a built-in-test anomaly that detected excessive drops of Electronic Control Unit (ECU) messages

Roundoff error propagation caused a timing mismatch. When the SIGI and FC clocks crossover, timing jitter occurs and occasionally data is sent to the ECU when it is busy, resulting in no responses. To avoid a recurrence, need to raise the tolerance level for missed messages -- changing one line of computer software code.

Why Quality, Safety and Mission Assurance?

One of the last steps in the launch sequence is to open the silo doors and retract the horizontal stabilizers that hold the missile in place. Sensors indicated that one of the three lateral support group mechanisms had not retracted, causing the missile to abort launch.

Test 3

Corrosion and dissimilar metals (galvanic corrosion) caused the failure. One mechanism failed to latch due to wrong crush blocks.

Test 1 EKV failed to separate due to an ASIC lead fatigue failure in the laser firing unit on the EKV

Inadequate laser firing unit qualification test. Stiffening foam was removed from a board. The random vibration test was conducted without power-on so the problem could not be detected on the ground.

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MDA LESSONS LEARNED ROADSHOW (CONT’D)

Company Group Location

Northrop Grumman KEI Fair Lakes, VANorthrop Grumman MA Leads Reston, VALockheed Martin Aegis Moorestown, NJRaytheon RMS Woburn, MA Raytheon IDS Tewksbury, MATHAAD Program Office Huntsville, ALLockheed Martin THAAD & MKV Sunnyvale, CALockheed Martin THAAD Huntsville, ALLockheed Martin BV+ Courtland Elkton, MDAF SPO ABL Albuquerque, NMRaytheon RMS Tucson, AZSpectrum Astro NFIRE, STSS Gilbert, AZNorthrop Grumman STSS Los Angeles, CAAerojet MDA Sacramento, CA

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WHAT MDA HAS DONE TO INCREASE SQMA

• Increasing Quality Assurance rigor by:- Organizing for Mission Success- Changing Culture - Onsite MDA Mission Assurance Representatives (MARS)- MDA Assurance Provisions (MAP) & PMAP- Defense Contract Management Agency (DCMA)

Delegation of Authority Letter- System and Range Safety Oversight- Safety and Occupational Health

Getting Back to the Basics

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GOING FORWARD

• Change Customer and Contractor Cultures- Corporate Leadership and UNIVERSAL, CONTINUING Commitment

• Increase Process Discipline – Supplier Management- Management and Engineering Process Rigor- Establish and Maintain Basic Set of SYSTEM Standards (MDA MAP

– Core Standards)- Ensure basics are CONTINUOUSLY accomplished by BOTH

Customer and ALL Supplier Tiers- Ensure Systems Engineering, Disciplined Test Management, Quality

Management, Risk Management, Configuration Management

• Organize for Mission Success- Clear, continuing organizational accountability- Robust engineering organization- Independent, capable SQMA organization and personnel

mda qsma solutions mr. edward jopson assistant director mda/qsi cqsdi march 27 2007

Documents

mda safety

mda director slide

mda personnel

safety slide

mda qsma solutions

worldclass safety

mdaqs director quality

bsos safety personnel