review of us air force parts, materials and …the pmp issue impact of acquisition reform •...
TRANSCRIPT
© The Aerospace Corporation 2009Page 1
© The Aerospace Corporation 2009
Review of US Air Force Parts, Materials and Processes (PMP)
Requirements
Larry HarzstarkDr. Steven Robertson
The Aerospace Corporation(310) 336-5883
10-16-09
© The Aerospace Corporation 2009Page 2
Topics of Discussion
• Introduction• Unique Requirements for Space PMP• The PMP Issue - Impact of Acquisition Reform• The Way it Was: Prior to Acquisition Reform• The Way It Is: PMP Issues Today• Program Objectives to Reverse PMP Trends• Government Flow down• Summary of 5235A Requirements• Summary of 5236A Requirements
© The Aerospace Corporation 2009Page 3
Introduction
• This presentation will provide an overview of how the US Air Force views Parts, Materials and Processes for space applications and the requirements it imposes on contractors building hardware
© The Aerospace Corporation 2009Page 4
PMP for Space Is Unique
© The Aerospace Corporation 2009Page 5
Space PMP Requirements
© The Aerospace Corporation 2009Page 6
Unique Requirements for Space PMP
• Cannot repair or service during mission operation– Requires long mission life, high quality, high reliability, very high MTTF,
derating of application operational conditions• Radiation hardness (or tolerance) required, both total dose and single
event effects• Spacecraft charging• Contamination control
– Within parts to improve reliability– Outgassing requirements to prevent contamination of sensitive surfaces
• Operates in vacuum– Can cause thermal dissipation/stress issues
• Possible High shock, temperature cycling and temperature extremes• Degradation from aging• Atomic oxygen and micrometeoroids• Obsolescence management
Unique space environments and requirements shape PMP designs, screening and qualification practices
© The Aerospace Corporation 2009Page 7
The PMP IssueImpact of Acquisition Reform
• Acquisition trends believed to have contributed to erosion of parts, materials and processes (PMP) practices
1980Space Level Parts
1990AcquisitionReform
2000 2005
Risk
PMPPractices
SystemComplexity
To Reverse PMP Space System Trends
1970MIL Level Parts
PMP Revitalization Goal:Reverse Practices and Risk Trends
Future
© The Aerospace Corporation 2009Page 8
The Way it Was:Prior to Acquisition Reform
• Rigorous PMP specs & standards contractually implemented– Parts Selection and baseline quality levels (mandatory use of space
level parts)– Right of government approval– Parts derating– PMP Control Board (PMPCB) management– Verification/validation of part compliance to requirements– Destructive Physical Analysis (DPA) of all parts– Subcontractor oversight and requirements flow down
• Requirements for participation in GIDEP (Government Industry Data Exchange Program)
• Deliveries of PMP plans, lists, failures, etc.• Commercial off-the-shelf components not allowed – Extensive review
processes for any usage• Contractors well staffed with experienced component engineers
Rigorous requirements & practices provided good framework & visibility for PMP management
© The Aerospace Corporation 2009Page 9
The Way It Is:PMP Issues Today
• Space parts industry has little clout with part suppliers• Space lines moved off-shore, becoming more difficult to monitor• Test elimination due to increased part complexity and optimization• Reduced requirements flow down and oversight across the board due
to resources and priorities• Deficiencies in new technology insertion practices• Reduced PMP requirements, staffing/resources and PMP practices
– Limited space qualification & requirements validation practices– Limited use of PMPCBs– Limited DPA
• Increased outsourcing and reduced technical expertise• Limited data sharing
Erosion in Practices & Increased Risk of PMP Failures
© The Aerospace Corporation 2009Page 10
Program Objectives to Reverse PMP Trends
• Reverse PMP space acquisition trends through comprehensive strategic PMP Program management– Strong PMP engineering, management
processes and oversight across National Security Space
– Rigorous PMP processes– Strong cross program communication – Implementing practices that increase
likelihood problems will be prevented or discovered early and their proliferation and impact minimized
© The Aerospace Corporation 2009Page 11
Government Flow down
• The government will flow down PMP requirements as part of the contract– Currently use the Aerospace PMP Technical Operating
Reports (TOR)• The government will have access and
knowledge of how the prime contractor implements the PMP program
• The prime contractor will review the requirements and flow down the applicable requirements to the subcontractors
• The prime contractor will monitor the PMP compliance by the subcontractors
© The Aerospace Corporation 2009Page 12
Summary of 5235A Requirements
• TOR 2008-8583-5235A is the PMP Management requirements
• Forward – Use of non-government standards requires contractor
to ensure review of changes– Requirements for non repairable satellites, experimental
missions, and launch vehicles are the same – May be tailored, especially for experimental missions– As applicable when referenced in the contract
• References and ties back to technical requirements TOR 2008-8583-5236A
• Definitions – modified and added clarification (i.e., COTS, manufacturing baseline, New PMP Technology, etc)
© The Aerospace Corporation 2009Page 13
Summary of 5235A Requirements• PMP Overall Program – requires a plan to
define how PMP program will be implemented• Existing Design or re-procurement of existing
design – Previously performed reliability and worst-case
analyses may be used to satisfy the requirements for re-procurement of existing designs except in cases where new parts are used to replace obsolete ones
• New Technology Requirements– Appendix D with detailed information on what is
necessary for insertion • PMPCB
– Government retains the right of review and disapproval of PMPCB decisions while present or within a mutually agreeable period
© The Aerospace Corporation 2009Page 14
Summary of 5235A Requirements
• Delegation of PMPCB meetings– Requirements to allow delegation for subcontractor
PMPCB meetings• PMPCB Responsibilities
– Activities PMPCB is responsible for– Data reviews– Parts, Materials and Processes Selection List– Part and Material Request approvals– Derating– DPA reviews– Etc
• Requirements Flow down– Appropriate flow down of requirements to
subcontractors
© The Aerospace Corporation 2009Page 15
Summary of 5235A Requirements
• PMP Selection Process– Space Quality Baseline– Requirement for Part and Material Request approval
on each item • PMP Procurement
– Order of precedence requirement; space baseline or SCD to the space requirements document
• PMP Characterization and Evaluation– Characterize parts and determine applicable
qualification requirements• Parts Derating Criteria
– Use of 5236A criteria or contractor criteria that is technically justified to PMPCB
– COTS treated as new technology
© The Aerospace Corporation 2009Page 16
Summary of 5235A Requirements
• PMP Drawing Review– Sign-off of drawings by applicable PMP representative
• PMP Prohibited and Restricted Usage– Pure tin >97% tin– Lead free solders– Emphasis on prohibited materials
• Plastic Encapsulated Microcircuits (PEMs) Usage– Requirements to allow usage of PEMs
• PMP Subcontract Management– Enhanced subcontractor monitoring
© The Aerospace Corporation 2009Page 17
Summary of 5235A Requirements• PMP Qual
– Defines requirement for all PMP to be qualified• Qual by Similarity
– Defines conditions upon which similarity/extension maybe utilized• Authorized Sources of Supply
– Added language to buy from OEM or franchised distributor to reduce counterfeit risk
• Customer Source Inspection– Defines conditions for what inspection should be performed by source when
applicable • Traceability
– Defines requirement for electronic, mechanical and material traceability• Incoming Inspection
– DPA– Compositional Analysis
• PMP Defective Material Control– Defines the system and control of defective PMP
• Re-use of Parts and Materials– Defines the conditions and approval process for the re-use of parts and
materials• Failure Analysis
– Defines the conditions when failure analysis should be performed
© The Aerospace Corporation 2009Page 18
Summary of 5235A Requirements
• Handling & Storage– Defines the controls for handling and storage of PMP
• Electro-Static Discharge (ESD)– Defines that parts sensitive to ESD must be controlled
and handled in accordance with established procedures
• DPA– DPA for all parts including mil-spec parts– Maintain (& provide if requested) electronic copies of
DPA reports• Shelf Life Control
– Parts shelf life control requirements enhanced• GIDEP
– Defines the participation in the GIDEP program and the responsibilities
© The Aerospace Corporation 2009Page 19
Summary of 5235A Requirements
• PMP Corrosion Control– Ensure all materials are evaluated and controlled
• Contamination Control Program– Material outgassing
• PMP Radiation Hardness Control– Defines the hardness assurance
requirement/methodology• Government Furnished Equipment (GFE)
– Requirements for handling and control of GFE• SPWG
– Support to annual Space Parts Working Group Meeting
© The Aerospace Corporation 2009Page 20
Summary of 5235A Requirements
• PMP Selection List– Approved list to select PMP
• PMP As Designed List– List defining PMP designed into system
• Added PMP As Built List Requirement– List defines actual PMP used in hardware
• Space Quality Baseline – Defines approved space level PMP not requiring
additional approvals
© The Aerospace Corporation 2009Page 21
Summary of 5236A Requirements• TOR 2008-8583-5236A is the PMP Technical
requirements• Definitions
– Clarified definitions of nominal and worst case• Derating
– Defines derating which enhances reliability• New Technology
– Defines requirement for new technology insertion• In-process Controls
– Defined the requirements for various in-process controls which are part type dependent
• Screening– Defines 100% testing to weed out marginal parts
• Qualification– Defines requirements for PMP qualification
• Quality Conformance Inspection – Defines lot acceptance criteria
• Qualification by Extension– Defines conditions upon which similarity maybe utilized
© The Aerospace Corporation 2009Page 22
Summary of 5236A Requirements
• Detailed Requirements– Each commodity type has own section detailing
– Screening– Qualification– Quality Conformance Inspection– Design and Construction– Reliability– Radiation – Process Controls– Prohibited Materials
– Enhanced hybrid element evaluation and requalification requirements
– Working on enhancing MIL-PRF-38534 to be in agreement– Added RF/microwave, surface acoustical wave and photonics
device sections– Changes to Printed Wiring Board sections– Resistor and capacitor sections modified to correct some
procurement issues observed by contractors
© The Aerospace Corporation 2009Page 23
Summary of 5236A Requirements
• Detailed Requirements– Each commodity type has own section detailing
– Screening– Qualification– Quality Conformance Inspection– Design and Construction– Reliability– Radiation – Process Controls– Prohibited Materials
– Enhanced hybrid element evaluation and requalification requirements
– Working on enhancing MIL-PRF-38534 to be in agreement– Added RF/microwave, surface acoustical wave and photonics
device sections– Changes to Printed Wiring Board sections– Resistor and capacitor sections modified to correct some
procurement issues observed by contractors
© The Aerospace Corporation 2009Page 24
Summary
• Space requirements for PMP are unique• Prior to acquisition reform, rigorous
requirements & practices provided good framework & visibility for PMP management
• Post acquisition reform, stringent PMP practices and requirements have eroded
• Aerospace PMP TORs have been generated and implemented on US Air Force contracts to enhance the PMP requirements and reduce the associated risks