Quality & Supplier Management

1. Quality & Supplier Management March 2008 Mike Gillette IPIC Quality Assurance Manager Northrop Grumman Corporation

2. Quality & Supplier Management Outline • History • Early Involvement • Proposal • ASMB • RFP • Source Selection • SDD • Production

3. 1957 1959 1961 1957 1964 1989 1968 1983 2000 SICBM Atlas Thor Titan MM I MM II MM III PK MM III SLE • 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) • 1970s • PK Go-Ahead (1972) • 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) • 2000+ • MMP • PSRE • SERV • REACT SLEP • 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 In An Uncertain World ICBMs Continue To Be Important To Our National Defense ICBMs – A continuing Success Story • ECS • ISMP • ICU

4. Supplier Management • 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 Objectives Results 1

5. Process for Supplier Management 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 changes • Review Class II changes • Attend selected on-site joint reviews of sub-tier suppliers Role of Program Manager and Engineers – Pre Award and Design • Conduct program reviews monthly • Cost, 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 Functional and Physical Configuration Audits Critical Design Review Acquisition Planning Low Rate Production Full Rate Production Deliver Accepted Products Contract/ Subcontract Awards Weapon System Integration Testing Production Readiness Reviews 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 visit • Establish 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 – 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 monitoring • Establish baseline for production qualification • As necessary, develop or disqualify supplier prior to production readiness review • End Item Data Packet definition to ensure traceability to requirements 2

6. 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

7. Early QA Involvement • 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

8. Early QA Involvement • 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

9. 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 Supplier Development Supplier Monitoring Supplier Audit IAW ISO9000/AS9100

10. 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

11. Periodic Audits F = Frequent S = Seldom Development Production Calibration System S S Tool Control S S Internal/External QA Audit results F F Data Management S F Configuration Management F F Product Identification S S Metrics and Metrics Analysis S F Training Records S F Procurement System F S Corrective Action System F F Supplier Management F F MRB S F Supplier Surveillance • Surveillance Includes Periodic Audits

12. 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

13. Supply Chain Management • 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

14. • • • • • • • • • • • • • • • • • • • • • • • • • • • Supplier Management Works at IPIC ~ 650 Prime WAWF Sell-offs per year (multiple items & locations) • 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 IPIC SQA Provides High Confidence in Fielded Product