2017 CQSDI Brief Mike Wadzinski Director Quality, Safety and Mission Assurance March 13, 2017

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1 2017 CQSDI Brief Mike Wadzinski Director Quality, Safety and Mission Assurance March 13, 2017 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Version: 2

2 Agenda Bottom Line Up Front (BLUF) QS Organization Update MDA Assurance Provisions (MAP) Rev B and Rev C Parts, Materials, and Processes (PMAP) Rev B and PM 86 MDA Assurance Reps (MAR) Locations and Regional Plan FY 16 Assessment Summary and Pareto Recent Quality Escapes Supply Chain Issues MDA-Defense Contract Management Agency (DCMA) Partnering Made for MDA Campaign Supplier Quality Days Conclusions 2

3 BLUF Why Quality is Important Even the smallest parts matter, and for that reason everyone, up and down the supplier chain, has a critically important job to ensure the Ballistic Missile Defense System (BMDS) is of the highest quality. This is an imperative for the nation. The cost of a defect may be the cost of a city (when an interceptor or another part of the BMDS does not work, we cannot do our mission) 3

4 QS ORGANIZATION QS QS Director (HSV) Mike Wadzinski LEGEND: MDA Civilian OGA Civilian Matrix MiDAESS QS Deputy Director (HSV) QS Chief Engineer (HSV) QS Fin Mgmt (HSV) QS Bus Ops (HSV) THQ Terminal High Altitude Area Defense (HSV) GMQ Ground-based Midcourse Program (HSV) QSV Verification (TUC) QSI BMDS Assurance Integration (COS) SNQ BMDS Sensors (HSV) ABQ Aegis BMD (DAHL) QSS BMDS Safety (HSV) QSA Mission Assurance (HSV) IPQ Israeli Cooperative Program (HSV) DVQ Advanced Technologies (HSV) QSC BMDS Safety Officers (COS) QSQ BMDS Quality (HSV) BCQ C2BMC (HSV) DVLQ Advanced Technology, Directed Energy & Sensor Technology (ALBQ) QSH Safety & Occupational Health (HSV) QSP Parts, Materials & Processes (HSV) TCQ Targets & Countermeasures (HSV) 4

5 MDA Assurance Provisions (MAP) Revision B Approved 13 June 2014 Implementing on all new contracts; assessing existing contracts A standardized set of 14 Quality, Safety, and Mission Assurance provisions, requirements, and processes for mission and safety critical items: MDA Assurance Provisions (MAP) 3.1 Management 3.2 Design and Development 3.3 Software and Firmware 3.4 Technical and Mission Assurance Reviews 3.5 Reliability, Maintainability, and Availability 3.6 Parts and Materials Control Program 3.7 Integrated Test and Evaluation Program 3.8 Test, Meas., and Diagnostic Equip. & Stds. 3.9 Interface Management 3.10 Configuration Management 3.11 Control of Nonconforming Items & Materials 3.12 Fabrication and Quality 3.13 Supplier Management 3.14 Safety 5

6 MAP Revision C Goal April 2018 Publication Primary focus will be to include new/updated SAE AS9100 requirements and new DoD directives for software assurance Will solicit industry input via MDA programs 6

7 Parts, Materials, and Processes (PMAP) Rev B Applicable Documents (References) Government and Commercial PMP Management Structure, Roles, and Responsibilities PMP Board, PMP Control Board, PMAG PMP Requirement examples Electrical, Electronic, and Electromechanical (EEE) Parts Materials Corrosion Prevention Prohibited Parts and Materials PMP Quality Requirements Counterfeit Parts Radiation Hardness Assurance PMP Qualification Commercial Off the Shelf (COTS) Management Failure Analysis Environmental Controls Handling Preservation, Packaging and Storage Appendices - Derating - Plastic Encapsulated Microcircuit (PEM) - COTS - Radiation Hardness - Assurance - Prohibited PMP - PMAP Data Items - Corrosion Prevention 7

8 MDA Policy Memo 86 Parts, Material and Processes Requirements Verification Program Managers will implement a PMP requirements verification process for all MDA mission and safety critical hardware contracts. The PMP verification process will be based upon the program s approved PMP plan and include a schedule of planed contractor-led onsite PMP baseline and maintenance verification assessment at subcontractor facilities. Emphasis on the following: Proper handling and storage of moisture sensitive EEE parts and wire Appropriate derating of EEE parts Receiving inspections to ensure XRF to detect pure tin, gold plated leads and PIND testing Proper assessment of product change notices (PCNs) Procurement from authorized sources 8

9 MDA/QS MAR Locations Aerojet Sacramento, CA Northrop Grumman Salt Lake City, UT OATK Magna, UT Missile Defense Integration and Operations Center (MDIOC) Colorado Springs, CO Eagle Picher Joplin, MO Raytheon Woburn, MA Raytheon Andover, MA Pacific Scientific Hollister, CA Vandenberg AFB Pacific Scientific Honeywell Tempe, AZ West Region Central Region East Region OATK Elkton, MD Lockheed Martin Moorestown, NJ Boeing Raytheon Huntsville, AL OATK Huntsville, AL OATK Chandler, AZ Honeywell Clearwater, FL Lockheed Martin Courtland, AL Ft. Greeley, AK Raytheon Tucson, AZ Aerojet Raytheon Lockheed Martin Camden, AR Aerojet/Coleman Orlando, FL 9

10 MAR Regional Plan (MRP) Purpose: Expand the footprint of the current MARs to cover additional companies utilizing a regional approach to supplier management. Background: Based on previous QS supplier assessments, many quality issues exist at lower tier suppliers. This plan was developed in Jan 2013 to provide visibility into the sub-tier supply chain, to identify similar issues and mitigate the risks. The MRP consists of small scale visits to suppliers (1or 2 MARs) that are conducted on a non-interference basis. Specified criteria are evaluated. MRP Phase I in 2014 covered 35 companies. Phase II in Feb 2015 added 42 companies. Phase III in Feb 2016 added 48 companies. Phase IV in work will add 20 companies. Companies are selected based on complexity of hardware, critical function of hardware within the system, history of quality issues and production status. Results: MARs work significant findings with MDA Program Offices. Companies have been very receptive to date. 10

11 FY 16 Assessment Summary FY16 Assessment Summary 7 Locations 377 Total Findings. 345 Deficiencies (90%), 32 Observations (10%) Tier Duration Date Completed # of Teams Notes 2 3 Days 20 Nov Finding 52 Deficiencies; 2 Observations 2 3 Days 29 Jan Findings 24 Deficiencies; 2 Observations. 1/2 9 Days 4 Mar Findings 117 Deficiencies; 13 Observations. 1/2 5 Days 8 Apr Findings 49 Deficiencies; 2 Observations. 2/3/ 4/5 4 Days 17 Jun Findings 54 Deficiencies; 7 Observations. 3 2 Days 21 Jul Findings 23 Deficiencies; 1 Observation. 2/3 3 Days 22 Jul Findings 26 Deficiencies; 5 Observations. 11

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13 Recent Quality Escapes CTE mismatch between parts, boards, potting, conformal coatings Failed electrical circuits - Improper application of adhesives and epoxies - Failed joints, interference Pure tin gaskets, leads and inadequate CCA conformal coating - Potential tin whiskers and FOD induced electronics card failure Inadequate assessment of product change notices for EEE parts - Resulted in delays in delivery until qualification could be completed Inadequate torque and/or loctite on fasteners - Significant rework Poor workmanship on wiring harnesses - Excessive gaps on insulation, exposed conductors, insufficient crimp Inadequate trend analysis for non-conformances, unverified failures - Contributed to failed test 13

14 Supply Chain Issues Flow down of MAP/PMAP Requirements to lower tier suppliers Verification of implementation of flowed MAP/PMAP requirements at lower tier suppliers Inadequate oversight/involvement with lower tier suppliers 14

15 MDA-DCMA Partnering Updated MDA and DCMA Overarching Memorandum of Agreement (OMOA) and Memorandum of Understanding (MOU) MDA & DCMA to conduct joint Technical Assessments on the MDA critical supply base MDA continues to train DCMA to MAP, PMAP Requirements MDA and DCMA updating program quality assurance surveillance including mandatory government inspections MDA and DCMA developed common Supplier Quality Questionnaire and share resultant data 15

16 Made for MDA Campaign Purpose Ensure all MDA suppliers of safety and mission critical components are aware that they are building products for MDA Ensure all MDA suppliers of safety and mission critical components are aware of the criticality of their components to safe and reliable MDA systems Products MDA Video Posters, Calendars, Badge Cards, Stickers Distribution MDA Website MDA Program Quality/Supplier Days Direct Distribution via mail MAP/PMPA Training Events 16

17 Recent/Upcoming MDA Program Quality/Supplier Days Targets Quality Day different suppliers in attendance Presentations by MDA Senior Leadership and MDA and Contractor QSMA Personnel: Importance of TC Quality to the Nation and Our Allies (MDA Director) Video: Target Flight Tests TC Overview (MDA Target PD) Challenges Requiring Quality Focus (MDA QSMA Director) Quality Approach for Sounding Rocket based Targets (Boeing Program Mgr. / Sr. Engineer) Suppliers as Partners (Boeing Program QSMA Director) Commitment to Process Control (Prime Program QSMA Director) Supplier Surveillance Boeing Program QSMA Director) MDA Technical Assessments Common Issues (MDA/QSV) Policy Memo 86 (MDA/QSA) Cybersecurity / Supply Chain Risk Management (MDA/EIR) Video: 33 Minutes AB SM-3 Quality Day different supplier in attendance Presentations by MDA Sr Leadership and MDA and Contractor QSMA Personnel: Importance of SM-3 Quality to the Nation & Our Allies (MDA Sr. Leader) Aegis BMD Role in the MDA Mission (MDA Program Exec) SM-3 Program & the Importance of Quality (MDA/RMS PDs) Challenges Requiring Quality Focus (MDA/RMS QSMA Directors) Supplier Engagement Activities (MDA/RMS Program QSMA Leads) Superior AMDS Supplier Sustainment (RMS SCM Director) Workshops: Joint Supplier Engagement Team (JSET) Panel Sub-Tier Supplier Collaboration (SSC) Special Process Controls First Article Inspections/AS9102 Parts, Material & Processes (PMP) Supply Chain Risk Management (SCRM) Covered Defense Information SCRM Cybersecurity/Malicious Intent 17

18 Recent/Upcoming MDA Program Quality/Supplier Days 2017 Tentative Quality/Supplier Days THAAD June, Huntsville AL GMD - June, Huntsville AL AB SM3 August, San Diego CA Sensors Sept/Oct, Location TBD Targets- Oct, Chandler AZ 18

19 Conclusions Quality is a requirement, not an option MDA continues to update standards and enforce lower in supply chain MARs increasing lower tier supplier assessments MDA Assessments finding more issues than they should Simple escapes can cause big problems Supply chain needs greater attention MDA continues to partner with DCMA to leverage capabilities MDA using Made for MDA Campaign and Supplier Quality Days to reach lower into supply chain to emphasize quality 19

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