NASA Quality Policy What’s Working? What’s New? Goddard Space Flight Center

1. NASA Quality Policy What’s Working? What’s New? Goddard Space Flight Center - Supply Chain Conference 2008 - Brian Hughitt NASA Office of Safety & Mission Assurance

2. Establish Requirements Assure Compliance with Requirements Organization Government Performing Work Contracting Agent Quality System Requirements Contract Quality Program Elements Prevention Detection/ Prevention Detection/ Correction Correction - NASA Quality Roadmap -

3. NASA Quality Roadmap

4. Federal Acquisition Regulations (FAR) Part 46, Quality Assurance Contract quality requirements: Requirements in the contract relating to the quality of the product and those contract clauses prescribing inspection, and other quality controls incumbent on the contractor, to assure that the product conforms to the contractual requirements. The extent of quality assurance is based upon the complexity and criticality of the contract item. Government contract quality assurance: The various functions, including inspection, performed by the Government to determine whether a contractor has fulfilled the contract obligations. The Government is required to perform “all actions necessary” to verify whether supplies conform to contract quality requirements.

5. “ Work that is both critical and complex shall be performed in accordance with the quality system requirements of AS9100.”NPD 8730.5, NASA Quality Assurance Policy Critical work is any hardware task that, if performed incorrectly or in violation of prescribed requirements, could result in loss of human life, serious injury, loss of mission, or loss of a significant mission resource. Complex work involves either: a) the design, manufacture, fabrication, assembly, testing, integration, maintenance, or repair of machinery, equipment, subsystems, systems, or platforms; or b) the manufacture/fabrication of parts or assemblies which have quality characteristics not wholly visible in the end item.

6. Management Responsibility Quality System Contract Review Design Control Document & Data Control Purchasing Process Control Training Servicing Corrective Action Control of Customer Supplied Product Product Identification and Traceability Inspection and Testing Control of Nonconforming Product Handling, Storage, Packaging, Preservation and Delivery Control of Quality Records Internal Quality Assessment Statistical Techniques AS9003 Inspection and Test Quality System Noncomplex Product A hardware item whose conformance of key characteristics can be wholly established through measurement, inspection, and/or test of the end item

7. “The Contractor shall maintain an inspection system acceptable to the Government covering supplies under this contract and shall tender to the Government for acceptance only supplies that have been inspected in accordance with the inspection system and have been found by the Contractor to be in conformity with contract requirements.” US Federal Acquisition Regulations (FAR) Inspection Clause

8. Quality System Material Identification, Damage, Count Right of Access Flow Down Requirements Certificate of Compliance (C of C) Certificate of Compliance Raw Material Certificate of Compliance - Calibration Special Process Certification Calibration System Configuration Management System Change Authority Critical Processes Government Source Inspection (GSI) Contractor Source Inspection (CSI) First Article Inspection Nondestructive Inspection (NDI) / Nondestructive Test (NDT) Certification 100% Attribute Clauses Limited Operating Life Items Limited Life and Age Control (Shelf Life) Packaging Requirements Packaging Handling & Labeling Shipping Documents Nonconformance Reporting GIDEP Record Retention Electrical Wire and Cable Test Report EEE parts Date of Manufacture EEE Single Lot / Date Code Electrostatic Discharge (ESD) Protection Program High-Strength Fasteners Pressure Vessels Solvent Containers ARP9009AerospaceContract Clauses

9. Certificate of compliance- Raw materials “Organization will include with each shipment the raw material manufacturer's test report (e.g., mill test report) that states that the lot of material furnished has been tested, inspected, and found to be in compliance with the applicable material specifications. The test report will list the specifications, including revision numbers or letters, to which the material has been tested and/or inspected and the identification of the material lot to which it applies. When the material specification requires quantitative limits for chemical, mechanical, or physical properties, the test report will contain the actual test and/or inspection values obtained. Contract Quality Clause Example

10. CIRCULAR NO. A-119 MEMORANDUM FOR HEADS OF EXECUTIVE DEPARTMENTS AND AGENCIES SUBJECT:  Federal Participation in the Development and Use of Voluntary Consensus Standards and in Conformity Assessment Activities Your agency must use voluntary consensus standards in its regulatory and procurement activities in lieu of government-unique standards unless use of such standards would be inconsistent with applicable law or otherwise impractical. (1) "Use" meansincorporation of a standard in whole, in part... (2) "Impractical" includes circumstances in which such use would fail to serve the agency's program needs; would be infeasible; would be inadequate, ineffectual, inefficient, or inconsistent with agency mission; or would impose more burdens, or would be less useful.

11. From: Lloyd, James D. (HQ-GA000) Sent: Tuesday, June 26, 2007 8:05 AM To: Hughitt, Brian (HQ-GD000); Oconnor, Bryan (HQ-GA000) Cc: Stamatelatos, Michael G. (HQ-GD000); Malone, Roy W. (MSFC-QD01) Subject: RE: CxP Workmanship Standards Status Brian and Bryan, I went to a CxP brief to the Administrator on Friday … and Mike clearly and repeatedly indicated that NASA does not have the market cornered on how to do everything related to space. In general, in some cases he said we are far behind the free market! He wants the preference to be national consensus, government consensus (looking closely at DOD specs and standards), NASA standards and, lastly, center-based unique standards. His premise is that being unique without reason and when not warranted is costing money. The risks need to be fully understood for complying or not complying with this order of precedence. Jim Voluntary Consensus vs NASA Standards- NASA Administrator Comments -

12. Transitioning to Voluntary Consensus Standards J-STD-001 Space Addendum (Soldering): NASA Proposal in Industry Coordination. CxP requirements carried in parallel. Address gaps: a) Additional requirements b) Modification to VCS Gap analysis to ensure technical adequacy Widespread & Consistent Usage 1 2 Standards Lifecycle IPC-A-620 Space Addendum (Harness Mfrg): Preparing “shall” list in preparation for gap analysis of forthcoming draft. NASA Chairs IPC Working Group. ANSI/ESD S20.20 (Electrostatic discharge): Implementation Plan for Cross-Agency Use 3 ANSI/ESD S20.20: Currently examining requirements for tools & gloves Document Stewardship

13. Soldering (Workmanship) – J-STD-001D / DS Non-Destructive Evaluation – NAS/ASTM/SAE (various) Metrology / Calibration – ANSI/NCSL Z540.3 Electrostatic Discharge Protection – ANSI/ESD S20.20 First Article Inspection – AS9102 QMS for Maintenance Organizations – AS9110 QMS for Distributors – AS9120 Inspection Sampling Procedures – ANSI/ASQC Z1.4/Z1.9 Variation Management – AS9103 Contract Quality Clauses –ARP9009 Voluntary Consensus Standards Adopted by NASA

14. Risk

15. The quality system provides assurance that all requirements are complied with- those that matter a lot and those that don’t matter as much. For highly complex and critical operations, MANY requirements that matter a lot. NASA = HIGHLY CRITICAL AND COMPLEX Don’t waste your time assuring requirements that don’t matter much. Be deliberate, be watchful, be smart. Careful planning and measurement of risk is the inviolable first step before quality program execution.

16. It is NASA policy to mitigate risks associated with noncompliance. NPD 8730.5 Determination of risk considers: • the likelihood of noncompliance • the consequences associated with noncompliance • the maturity, complexity, criticality, importance & the value of work performed • past performance

17. Separate the vital few from the trivial many Joseph Juran

21. One NASA Joint Audit Planning Committee

23. Authority The United States Code of Federal Regulations (CFR) Title 15, Part 287, Guidance on Federal Conformity Assessment Responsibilities of Federal Agencies: Coordinate its quality assurance activities with those of other appropriate Government agencies and with those of the private sector (Sec 287.1(a)). Participate in efforts designed to improve coordination among governmental and private sector conformity assessment activities (Sec 287.4(g)). Conduct joint supplier audits and share conformity assessment information among agencies (Sec 287.4(h)). Use the results of private sector or other governmental conformity assessment activities to schedule audits more effectively (Sec 287.4 (e)) Joint Audit Planning Committee

24. Supplier agrees in advance that data generated from audits will be shared among JAPC member organizations Supplier validates that JAPC audit data is factually accurate and that it does not contain trade secrets, confidential commercial or financial data, or export controlled information JAPC member organizations are not permitted to audit suppliers from which they routinely or specifically compete with for the same or similar work JAPC member organizations are required to protect supplier information received Legal Propriety

25. ATK Launch Systems Ball Aerospace and Technologies Corporation Boeing Space Exploration California Institute of Technology Jet Propulsion Laboratory (JPL) The Johns Hopkins University/Applied Physics Laboratory (JHU-APL) Lockheed Martin Space Systems Northrop Grumman Space Technology Orbital Sciences Corporation Pratt & Whitney Rocketdyne Raytheon Missile Systems United Space Alliance NASA Headquarters NASA Centers DCMA Missile Defense Agency (National Reconnaissance Office) JAPC Member Organizations

26. A supplier for which an organization desires a higher level of assurance than that provided by the QMS certification process. Considerations for identification of JAPC suppliers include: importance of product complexity of product maturity of product/process new supplier history of quality problems special processes not covered by Nadcap Identification of Prospective JAPC Suppliers

28. Aerojet Corporation Honeywell Defense & Space Electronics Systems Honeywell Space Systems Division L-3 Communications Cincinnati Electronics Merrimac Industries Moog Inc., Systems Group Starsys, Inc. Vacco Industries Hamilton Sundstrand – Rockford Hamilton Sundstrand – Windsor Locks Emcore AMPAC Reinhold Industries Parker Hannifin Aeroflex Laboratories Microsemi JAPC Suppliers(Audited or Scheduled)

29. Supplier Calendar (proposed)

30. Bumps along the road: Audit scope Competitors Thanks, but no thanks… Feedback loop. Recalibrating the JAPC

31. QUALITY MANAGEMENT SYSTEM Control of outsourced processes 4.1 Configuration Management 4.3 / 7.5.3 PRODUCT REALIZATION Identification and Inspection of Key Characteristics 7.3.3.9/ 7.5.1/ 8.1 Supplier Quality Management (Purchasing) 7.4 Process control 7.5.1 - Documentation of processes - Control of key characteristics - In process verification points Criteria for workmanship Validation, Monitoring, and Measurement of Special Processes 7.5.2 / 8.2.3 Identification of Monitoring/Measurement Status 7.5.3 Traceability of Product to Records of Objective Quality Evidence 7.5.3 Preservation of Product / Work Environment 7.5.5 / 6.4 Electrostatic Discharge Foreign Object Debris/Damage 7.5.1.i - Cleanliness MEASUREMENT, ANALYSIS AND IMPROVEMENT Internal Audit 8.2.2 Monitoring, Measurement, and Control of Key Characteristics 8.2.4 Control of Nonconforming Product 8.3 Corrective Action 8.5.2 Audit Scope- High Risk QMS Elements -

32. “Audit results are withheld from JAPC member organizations with whom the supplier routinely or specifically competes for the same or similar work, whether such work is awarded by a governmental organization or in commercial trade. (note: this access limitation does not apply to JAPC member organizations that have a current open contract with the audited supplier where such contract includes an access provision for the conduct of quality assurance surveillance activities).” JAPC Supplier Invitation Letter Competitors

33. “Suppliers declining JAPC membership (or failing to respond) shall be notified by the lead JAPC organization of their intention to perform a quality system audit, and shall be provided a second invitation for the supplier to become a JAPC supplier.” JAPC MOU, Rev A Thanks, but no thanks…

34. “Providing continuous improvement feedback to third party, Industry Controlled Other Party (ICOP), and Government programs which serve to assess the conformance and/or effectiveness of supplier quality management systems or quality system processes.” JAPC MOU, Rev A JAPC Feedback Loop

35. Knowledge Café

36. Quality Taxonomy 36

37. Device lead condition shows parts were used Marking indicates an Op Amp from ADI… … but contains die for a Voltage Reference from PMI Evidence of prior marking for a part with inferior performance … Part number indicates a CLCC package, but this package is a CDP… … accompanied by bogus test report Counterfeiting Retopping Remarking

40. Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives. William A. Foster