copyright 2005 northrop grumman corporation 0 quality & supplier management march 2008 mike...

Copyright 2005 Northrop Grumman Corporation 1

Quality & Supplier Management

March 2008

Mike GilletteIPIC Quality Assurance ManagerNorthrop Grumman Corporation


Quality & Supplier Management

OutlineOutline

History Early Involvement

Proposal ASMB RFP Source Selection

SDD Production


ICBMs – A continuing Success Story

•ECS•ISMP•ICU

Atlas Thor Titan MM III PK SICBM

1957 1957 1959 1961 1964 1968 1983 1989

MM IIMM I MM IIISLE

2000

1950s•Atlas 1st Launch (1957)•Thor 1st Launch (1957)•Titan 1st Launch (1959)

1950s•Atlas 1st Launch (1957)•Thor 1st Launch (1957)•Titan 1st Launch (1959)

1960s•MM I 1st Launch (1961)•MM II 1st Launch (1964)•MM III 1st Launch (1968)

1960s•MM I 1st Launch (1961)•MM II 1st Launch (1964)•MM III 1st Launch (1968)

1970s•PK Go-Ahead (1972)

1970s•PK Go-Ahead (1972)

1980s•PK 1st Launch (1983)

•SICBM Go-Ahead (1983)•PKRG Go-Ahead (1986)

•SICBM 1st Launch (1989)

1980s•PK 1st Launch (1983)

•SICBM Go-Ahead (1983)•PKRG Go-Ahead (1986)

•SICBM 1st Launch (1989)

1990s•REACT

•GRP•PRP

•ICBM Prime Award (1997)

1990s•REACT

•GRP•PRP

•ICBM Prime Award (1997)

2000+•MMP•PSRE•SERV•REACT SLEP

2000+•MMP•PSRE•SERV•REACT SLEP

In An Uncertain World ICBMs Continue To Be Important To Our National Defense

In An Uncertain World ICBMs Continue To Be Important To Our National Defense

Hold Targets at Risk Provide Deterrence Against Attack Rapid Receipt and Response to Emergency Action Messages

(EAMs) Flexible Response Against Our Enemies Should Deterrence Fail

A Critical National

Asset

A Critical National

Asset


Supplier Management

Key Features Benefits Well established process to identify and

qualify new vendors Programs executed on plan with no

substandard parts or components delivered to field

Focus on developing and qualifying vendors to meet our high standards before production starts

Understanding of our needs as a customer and sound basis for shared success

Monitor suppliers, during design and production, for successful corrective actions addressing variances from plan

Ensures timely awareness of difficulties and provides time to correct without impact to customer

Multi-tier vendor audits and assessments

Reinforces commitment to quality products throughout supply chain

Suppliers evaluated for ability to consistently produce quality products

Vendor oversight approach adapted to needs of supplier

ObjectivesObjectives No quality escapes to the field Quality is built-in, not

inspected-in

Over 3500 end items delivered to field since 2002 with essentially no quality issues

ResultsResults

1


Process for Supplier Management

Acquisition Planning

Contract/ Subcontract

Awards

Deliver Accepted Products

Critical Design Review

Functional and Physical

Configuration Audits

Weapon System Integration

Testing

Production Readiness Reviews

Low Rate Production

Full Rate Production

Role of Program Manager and Engineers – Pre Award and Design

Conduct program reviews monthlyCost, Schedule, Technical, Risk, and Corrective Actions to Variances

Conduct independent technical review for design reviews/audits Establish Weapon System Integration test procedures Monitor progress toward production readiness

Role of Program Manager and Engineers – Pre Award and Design

Conduct program reviews monthlyCost, Schedule, Technical, Risk, and Corrective Actions to Variances

Conduct independent technical review for design reviews/audits Establish Weapon System Integration test procedures Monitor progress toward production readiness

Role of Program Manager and Engineers - Production Conduct program reviews every 6-8 weeks

Cost, Schedule, Technical, Risk and Corrective Actions to Variances

Approve Class I changesReview Class II changes

Attend selected on-site joint reviews of sub-tier suppliers

Role of Program Manager and Engineers - Production Conduct program reviews every 6-8 weeks

Cost, Schedule, Technical, Risk and Corrective Actions to Variances

Approve Class I changesReview Class II changes

Attend selected on-site joint reviews of sub-tier suppliers

Role of Quality Engineers – Pre Award and Design Qualify supplier for specific work scope Monitor supplier processes for compliance

Establish and monitor corrective actions when necessary

Team with first tier supplier on supply chain monitoringEstablish baseline for production qualificationAs necessary, develop or disqualify supplier prior to production readiness review

End Item Data Packet definition to ensure traceability to requirements

Role of Quality Engineers – Pre Award and Design Qualify supplier for specific work scope Monitor supplier processes for compliance

Establish and monitor corrective actions when necessary

Team with first tier supplier on supply chain monitoringEstablish baseline for production qualificationAs necessary, develop or disqualify supplier prior to production readiness review

End Item Data Packet definition to ensure traceability to requirements

Role of Quality Engineers - Production Participate in on-site joint reviews of sub-tier suppliers Conduct on-site inspection of process compliance during each

site visitEstablish and monitor corrective actions when necessary

Conduct three-way (Government, Prime, Supplier) buy-off of products

Resolution of material & process discrepancies (MRB)

Role of Quality Engineers - Production Participate in on-site joint reviews of sub-tier suppliers Conduct on-site inspection of process compliance during each

site visitEstablish and monitor corrective actions when necessary

Conduct three-way (Government, Prime, Supplier) buy-off of products

Resolution of material & process discrepancies (MRB)

2


Early QA Involvement

Proposal Phase Participate in Alpha Negotiations QA Submits a Basis of Estimate Participate in Supplier Proposal Evaluation Approver of Contract Deliverables Definition Participate in the Final Proposal Review



Acquisition Strategy Make Buy (ASMB) SQE is a Signature SEIT is a Participant

Request For Proposal (RFP) Contains a Mission Assurance Requirements

Document Written by SQE in Concert With MA Team

SQE Reviews the Request for Proposal Supplier Selection

Pre-award Assessment Participate in Source Selection



Review & approval of Supplier/Subcontractor QA Plans Conduct Sub-tier Supplier Assessment Support Formal Reviews

SRR PDR CDR TRR PRR

Qualification Testing Support Functional and Physical Configuration Audits Conduct First Article Acceptance

Incoming Inspection Verification In-Process Audit and Inspection Verification


Supplier Development

Process Owner Reviews Failure Modes and Effects

Analysis (FMEA) Develop/Review Work

Instructions Define/Develop/Document

Critical Processes Assist in Obtaining ISO

Compliance Review and Verification

of Audit Results/Findings

SubTier

QualitySurvey

Current Rating

CommentMitigation

RatingMitigation Plan

1 Date Y

G

2 Y

G

3 R

G

3 Y

G

2 Y

G

3 Y

G

3 R

G

R Y Minor Compliance Issues G ISO CompliantMajor Compliance Issues

Subcontractor

Supplier A

Supplier B

Supplier MonitoringSupplier Monitoring

Section: Overview

Supplier Name :

Date: March 10-11, 2004 NGMS Certification Audit Date

Supplier Site :

Supplier S

elf-

Assessm

ent

Poin

ts

NG

MS A

udit

Poin

ts

Tota

l Possib

le

Poin

ts

NG

MS A

udit

Poin

ts

Prime 19160 Form 260 Green Yellow Red

4.0 Quality Management System 13 2 0 54 43 60 71.7%5.0 Management Responsibility 10 6 1 63 43 68 63.2%6.0 Resource Management 6 2 0 30 23 32 71.9%7.0 Product Realization 10 1 0 41 32 44 72.7%7.3 Design and Development 6 6 3 54 33 60 55.0%7.4 Purchasing 11 3 3 56 42 68 61.8%7.5 Production & Service Provision 15 1 2 60 50 72 69.4%7.6 Control of Monitoring Measuring 8 1 1 40 27 40 67.5%8.0 Measurement, analysis and improvement 16 1 2 71 52 76 68.4%8.3 Control of Nonconforming Product 3 2 3 29 16 32 50.0%8.4 Analysis of Data 3 0 0 12 9 12 75.0%8.5 Improvement 7 2 3 44 28 48 58.3%N/ A Foreign Object Elimination 0 0 0 0 0 N/ A

ESD Program 17 0 1 72 66 72 91.7%N/ A Software 0 0 0 0 0 N/ A

554 398 612

90.5% 65.0% 65.0%

Suppliers Quality Management System has been properly documented in accordance with ISO 9001:2000 standards. Necessary Processes have been identified which pertain to their application throughout the organization. Assessment results indicate several major and minor deficiencies in understanding and meeting requirements, obtaining results of process improvement and effectiveness, and continual improvement of process based on objective measurement.

NGMS Approval

Supplier Assessment and CertificationRevision: Initial Release

Notes:

Total Points

Scores = Total Points / Total Available Points

Supplier Audit IAW ISO9000/AS9100Supplier Audit IAW ISO9000/AS9100


Supplier Monitoring

Surveillance Plan Defines the Surveillance Program Enforces the Mission Assurance Requirements Surveillance Includes Mandatory Inspection Points

Production Processes Focus on Process Improvement Lean/Six Sigma Quarterly Scorecard Input Corrective Action


Supplier Surveillance

FSMRB

FFSupplier Management

FFCorrective Action System

SFProcurement System

FSTraining Records

FSMetrics and Metrics Analysis

SSProduct Identification

FFConfiguration Management

FSData Management

FFInternal/External QA Audit results

SSTool Control

SSCalibration System

ProductionDevelopmentPeriodic Audits

F = Frequent S = Seldom

•Surveillance Includes Periodic Audits


Supply Chain Management

Product Acceptance Verification That All Items Are Being Delivered

Hardware, Software, Documentation, Test Results, Spares, Data and Records

Verification That All Items Meet Contractual Requirements

Item Built IAW the Documented System All Requirements Are Verified Records Are Available As-Built Configuration Is Controlled


Product Acceptance Continued Define Data Package

As-Built Configuration (Indentured Parts List) Proof of Traceability Requirements Having Been Met Open Action Items Are Documented Non-Conformances are Properly Corrected Waivers and Deviations are Documented Incorporated ECP’s Are Listed Review Build Paper

Recording of Critical Parameters Certificate of Conformance Accompanied With Objective

Evidence Incident Reports

Supply Chain Management


Supplier Management Works at IPIC

Summary Early Participation in a Program Mission Assurance Requirements

Document Accompanies Every RFP Assessments are Accomplished Upfront Surveillance Plans are Defined and

Followed Product Acceptance/Delivery is Exhaustive

and is Unacceptable Without Objective Evidence

Early Recognition of Supplier Development Requirements

Manage the Complete Supply Chain Lessons Learned are Liberally

Incorporated

~ 650 Prime WAWF Sell-offs per year (multiple items & locations)

~ 650 Prime WAWF Sell-offs per year (multiple items & locations)

IPIC SQA Provides High Confidence in Fielded ProductIPIC SQA Provides High Confidence in Fielded Product

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copyright 2005 northrop grumman corporation 0 quality & supplier management march 2008 mike...

Documents

s pk goahead

s atlas

sicbm goahead

field quality

quality escapes

quality issues

pkrg goahead

supplier objectives