2013 beya seminar: quality assurance increasing workfore effectiveness expertise and reliability

QUALITY ASSURANCE:

INCREASING WORKFORCE

EFFECTIVENESS, EXPERTISE,

AND RELIABILITY

Presenters:

Dennis Owens, Patrice Gregory, and J. Anthony Wingate

Friday, February 8, 2013 | 8:15 a.m. – 9:30 a.m.

Washington Marriott Wardman Park | Maryland Suite A

Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly

owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy’s National Nuclear Security

Administration under contract DE-AC04-94AL85000.

SAND #: 2012-7175 P

Unlimited Release (UR)

Topic Requirements:

Quality Assurance: Increasing Workforce Effectiveness, Expertise, and Reliability Quality assurance must ensure all areas of the organization are meeting performance standards as set forth in internal quality assurance surveillance plans. Clear roles and responsibilities, performance objectives, and methods of measuring and monitoring quality ensure that the vision of the organization is properly implemented. How can you promote the importance and best practices of sustaining and implementing quality assurance programs? At the end of this session, participants will be able to:

a. Understand how to ensure teams are aligned with values of quality assurance b. Discuss methods to improve reliability, accountability, and performance c. Explore methods of measuring and monitoring quality

Learning Outcomes: Participants will increase value and improve performance by designing and or assessing current Quality Assurance strategies that impact overall team and individual accuracy, efficiency, and reliability.

QUALITY ASSURANCE: INCREASING WORKFORCE EFFECTIVENESS, EXPERTISE AND RELIABILITY

D

• At the end of this session, participants will be able to:

a. Understand how to ensure teams are aligned with values of quality assurance (QMS design)

b. Discuss methods to improve reliability, accountability, and performance (LSS CI event strategy)

c. Explore methods of measuring and monitoring quality (Performance Auditing against QP and objectives)

Objectives:


D

Dennis Owens J. Anthony Wingate Presenter Bios:


J. Anthony Wingate manages the Subsystem and Component Quality Engineering I department at Sandia National Laboratories in Albuquerque, New Mexico. His organization provides R&D Product Qualification Engineering support to Sandia’s nuclear mission programs. Anthony’s career began as a summer intern at WKM Value Company and Houston Lighting & Power and GE Lexan Plastics. In 1987 he joined prestigious Manufacturing Manage-ment Program (MMP) at GE Lexan Plastics. In 1992 he joined Martin Marietta (now Lockheed Martin) as a process as a process engineer.

In In 1994 he was part of a small group of engineers selected to transfer generator technology from GE located in Pinellas, Fl. to Sandia National Laboratories (SNL) in Albuquerque, NM. While at SNL Mr. Wingate was responsible for quality and product engineering of generator technology. In 2007 he took an assignment as a Lead Project Engineer at Sandia’s Integrated Military Systems Development Center where he was responsible for design, fabrication and deployment of counter-measures on several test. In 2008 he was promoted to manager of the Subsystem and Component Quality Engineering department within the Surety Assessment, Engineering, and Analysis Center.

Mr. Wingate holds a certification in LM21 Lean Six Sigma and has contributed to several high-profile lean events for the Laboratory. He has received numerous awards such as 1998 and 2005 Sandia President’s Quality Awards, Sandia Awards for Excellence, 2005 and 2010 National Nuclear Security Administration (NNSA) Defense Programs Award of Excellence, and is the 2013 BEYA Affirmative Action Award recipient. Mr. Wingate received his Bachelor’s degree in Mechanical Engineering from Lamar University in Beaumont, TX. [email protected]

Dennis Owens manages the Defense Systems Quality Engineering department at Sandia National Laboratories (SNL) in Albuquerque, New Mexico. His organization provides R&D Systems Engineer-ing, Quality Engineering, and Quality Assurance support to Sandia’s Work for Others (WFO) Depart-ment of Defense projects/programs. Dennis’ career began at GE Aircraft Engines in 1988 in advanced composite fabrication and later turbine component manufacturing. In 1995 he joined Silmax, Inc., a semi-conductor and wafer reclamation company, as a a Quality Engineer. At Silmax, Mr. Owens was responsible for designing and

implementing the quality management system and supplier quality program. In 1999 Mr. Owens joined Allied Signal Power Systems (ASPS) as a Supplier Quality Engineer. At ASPS he was responsible for designing the quality management system and supplier quality programs. In 2001 Mr. Owens joined SNL as a Senior Quality Engineer. At Sandia his career has span from generator technology and software/tester qualification to Advanced Concept and Technology Development (ACTD) programs for Sandia’s Integrated Military Development Center (IMSDC) now Integrated Military Systems (IMS). Mr. Owens holds certifications in internal auditing (RABQSA), and LM21 Lean Six Sigma. From 2005-2007 he authored several articles in the American Society for Quality (ASQ) Quality Progress magazine on quality management, defect analysis, and continuous improvement. He has been invited to speak at NASA and ASQ conferences and is a 2013 BEYA Trailblazer award recipient. Mr. Owens received his Bachelor’s degree in Mechanical Engineering Tech-nology from New Mexico State University and a Master's of Arts degree in Organizational Management and Leadership from University of Phoenix. [email protected]

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mailto:[email protected]






Patrice Gregory is a Senior R&D Systems Engineer in the Subsystem and Component Quality Engineering II department at Sandia National Laboratories in Albuquerque, New Mexico. Her organization provides R&D Product Qualification Engineering support to Sandia’s nuclear mission programs. Patrice’s career began as a summer intern at NASA Ames Research Center in the Rotorcraft Division, where she was involved in the wind tunnel testing of a quarter scale V-22. She joined Sandia in 2011, where she leads the qualification efforts of magnetics components for various weapon systems. Patrice holds a Bachelor of Science degree in Mathematics from Spelman College, a Bachelor of Science degree in Mechanical Engineering from Georgia Institute of Technology, and Masters of Science and Doctor of Philosophy in Mechanical Engineering from the University of Maryland College Park. She performed her doctoral research on the comparison of interconnect failures of electronic components under rapid loading conditions. [email protected]


Patrice Gregory Presenter Bios: D




Expose you to :

a successful approaches in quality management

system (QMS) design and assessment

lean principles to ensure accuracy, efficiency,

and reliability in QMS performance

An Engineer’s perspective of quality applied to

research and development

Why? To help you extract simplicity out of complexity

Our Goal:


D

Defect- the lack of something necessary or desirable for

completion or perfection

Designed in Defects- a defect that which can be avoided only

through an alteration or redesign of the item.

Blunder- a stupid, careless, or thoughtless mistake

Waste- anything or process that does not add value to an item

Value- what the customer is buying or willing to pay for

Predictability ( vs. Reliability)-To state, tell about, or make

known in advance, especially on the basis of special

knowledge

Prevention- the action of stopping something from happening

As Quality Professionals we have to first change the way we think (or see) before we can influence others

Definitions:


D

2001: NG Production Center and the birth of Lean Six Sigma (LSS)

2010: Surety Assessment, Engineering, and

Analysis Center vision to improve operations Quality

What is the common theme from each of these stories?

Burning Platforms:

Business Platform

LEAN/SIX SIGMA

Tools

No More Budget No Schedule Relief

Minimal Inventory To Meet Schedule Demands

Competition

2007: Integrate Military Systems

Development Centers response to customer

(MDA) request


A

Unclassified – Unlimited Release (UUR)

Path to Excellence ISO9001:2008 LSS Project Team Accomplishments

We will describe the case study that yielded the following results: • Project completion, initiation to registration, within 7 months

• Project cost at $150k

• Quality Manual 12 pages in length and completed in 1 day

• Leveraged existing product realization process

• Eliminated legacy documentation waste

• QMS tied to Center strategic planning model

• Approach designed as a cost effective model for use by other organizations within Sandia National Labs

• Project recognized by National Nuclear Security Administration (NNSA)

An intuitive approach to defect prevention is key

Resources to stimulate your thinking

Case Study: Surety Assessment, Engineering and Analysis ISO Project (Sample Documentation): A


Understand how to ensure teams are aligned with values of quality assurance:

Management commitment, Manage by walk-around Attendance to staff meeting Direct support to Lean Events

Quality Policy and Quality Management System (QMS) Objectives that touch the critical parts of your business

Clear roles and responsibilities, Clearly defined at all levels through communication Unique review and planning through -out the organization

Requirements, Plan, Implement, Validate Product Realization


A

VSA Event Activities Time-Line: (Sample Documentation) A


“Switching” on the Light: (Sample Documentation) A


• Total Number of Participants:

1 Director, 2 Sr. Managers, 13 Managers, 4

Staff

• Event Cost Estimate:

High: $$

Low: $

Event Cost Estimate: (Sample Documentation) A


Discuss methods to improve reliability (predictability), accountability, and performance:

Application of Lean Six Sigma Tools (constraints, considerations, interactions, etc.)

Lean/Six Sigma Training

Well written Charter

Champions/Roles (accountability) Predictability (reliability) Prevention (performance) Sustainability (performance)


• Value Stream

• As-is Process

• Input-Process-Output

• Process Flow Diagram

• Quality Function Deployment

• Define CTQ’s

• Cause & Effect

• FMEA

• MSA

Define Process &

Customer Value

Measure Capability to

Meet Customer Needs

• Waste Identification

• Flow Diagrams

• Pull System Analysis

• To-be Process

• Variation

• Process Capability

• Sigma & DPMO Levels

• Value Stream Analysis

• Time Value Mapping

• Cycle Time & Efficiency

Improve & Innovate Process to Meet

Customer Needs

Analyze Process for

Improvement Areas

• Standard Operating Procedures

• SPC

• Process Metrics

• Process Modification

• Brain Storming

• DOE

• Kaizen

• Lean Processes

• Brain Storming

• 6s Applications

• Visual Controls

Control Process and

Sustain Performance

• Mistake Proofing

• Standard Work

Operating

Excellence

P

Communication Defect

EVENT / PROJECT CHARTER (Sample Documentation):


A

Champion: Rick Fellerhoff

Stakeholders: Mike Daily, Todd Jones

Team Members: Team #1: Dennis Owens- BB, Marlene Lucero-GB,

•Focus: Quality Manual

Team #2: J. Anthony Wingate-BB, Peggy Rhodes- GB, Ron Farmer, GB

•Focus: Center Related Processes

Team #3: J. Anthony Wingate-BB Dennis Owens- BB, Marlene Lucero & Peggy Rhodes- GB

•Focus: Dept specific operational plans

Preliminary Objectives: 1. Define the end state of the vision for the Center

2. Use ISO9001:2008 and Lean six sigma as tools to define, measure, analyze, improve, and control, operational processes and procedures that are in line with the Center vision, objectives and definitions of Center responsibility and authority throughout NW and WFO.

3. Define the strategy to execute multiple and parallel events in order to achieve registration within 6 months (December 2010)

4. Prove Center is Sandia’s resource with the technical expertise to design and implement cost effective quality management systems in an R&D laboratory environment

5. Recognition as Sandia’s “go-to” organization for QMS consultation

Customer Demand & Constraints: • Perceived understanding and value of ISO and Lean within the Center

• Industry Standard - ANSI/ISO/ASQ Q9001-2008

• Center:

• Website, Operational processes, Procedures, and Value propositions

• Vision, Objectives, Policy and VP memos

Process Information:

Event / Project Dates: Team 1 (July 2010), Team 2 (Aug 2010), Team 3 (Sept 2010)

Event/ Project Description: ISO 9001:2008 Registration

EVENT / PROJECT CHARTER

Value Stream Tie and/or Business Objective Tie: • Improve Center management practices

• Teach other Sandia organizations how to improve

• Paul Hommert Vision

Return on Investment: • Efficient, effective , and measureable operational

protocols for the Center

• 12300 Recognized as the Center of Excellence of NWC Quality in the area of Assessments and Engineered solutions

What management needs to understand in order to act

• Rule #1: the audit process objectives should only focus on determining the effectiveness of the quality policy statement and business objectives through cause and effect (e.g. the causal analysis chain of events)

• Rule #2: the audit process should report how/if “the system” is operating as an integrated unit

Design Defect

Talking Defect

Hearing Defect

Barrier Defect

WIFM (What’s In It For Me) Defect

N/C

What audit

finds

Communication Defect

+ Manpower Materials Machine

Measurement Methods Mother Nature (Environment)

Value/Goal

Explore methods of measuring and monitoring quality :


6 “M’s”

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What we want you to take away (golden nuggets) If you are a senior level leader, design and communicate your quality

vision in terms of an integrated system. Insist your audit program focus analyzes that vision and is based on value(or things your willing to pay for).

If you’re a line level leader, integrate the process of quality into your regular routine and communicate this often at your staff meetings as an expectation of performance.

If you're a staff member, show your commitment to your leadership’s vision by taking the time to understand your quality assurance program and be vocal about its value to your job. This will help us find the disconnects.

Flip the Script

Quality improvement is a journey, not a destination therefore, measure your successes and challenges with a “next steps” mentality.

Summary:


D

• You should now be able to: a. Understand how to ensure teams are aligned with

values of quality assurance (QMS design)

b. Discuss methods to improve reliability, accountability, and performance (LSS CI event strategy)

c. Explore methods of measuring and monitoring quality (Performance Auditing against QP and objectives)

Objectives:


D

Questions?


2013 beya seminar: quality assurance increasing workfore effectiveness expertise and reliability

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