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Mike Wadzinski
Director
Quality, Safety and Mission Assurance
March 13, 2017
2017 CQSDI Brief
Version: 2
DISTRIBUTION STATEMENT A.
Approved for public release;
distribution is unlimited.
2
• 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
Agenda
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)
4
QS ORGANIZATION
Bus Ops
(HSV)
QS
BMDS
Safety Officers
(COS)
QSC
Parts,
Materials &
Processes (HSV)
QSP
Mission Assurance
(HSV)QSABMDS Safety
(HSV)QSS
BMDS Quality
(HSV)
QSQ
Safety &
Occupational
Health (HSV)
QSH
BMDS Sensors
(HSV)
SNQ
Terminal High
Altitude Area Defense
(HSV)
THQ
Israeli Cooperative
Program (HSV)
IPQ
Ground-based
Midcourse Program (HSV)
GMQ
C2BMC
(HSV)BCQ
Aegis BMD
(DAHL)
ABQ
Targets &
Countermeasures (HSV)
TCQ
Advanced
Technologies (HSV)
DVQ
Advanced
Technology, Directed
Energy & Sensor
Technology (ALBQ)
DVLQ
LEGEND:
MDA Civilian OGA Civilian
Matrix MiDAESS
Verification
(TUC)
QSV
Chief Engineer
(HSV)QS
BMDS
Assurance
Integration (COS)
QS Director (HSV)
Mike Wadzinski
QS
Deputy Director
(HSV)
QS
Fin Mgmt
(HSV)
QS
QSI
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
6
• 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
MAP Revision C
7
• Applicable Documents (References)Government and Commercial
• PMP Management Structure, Roles,
and ResponsibilitiesPMP Board, PMP Control Board,
PMAG
• PMP Requirement examplesElectrical, 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
Parts, Materials, and Processes (PMAP)Rev B
•Appendices
- Derating
- Plastic Encapsulated
Microcircuit (PEM)
- COTS
- Radiation Hardness
- Assurance
- Prohibited PMP
- PMAP Data Items
- Corrosion
Prevention
8
• 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
MDA Policy Memo 86
9
MDA/QS MAR Locations
Vandenberg AFB
AerojetSacramento, CA
Pacific ScientificHollister, CA
OATKChandler, AZ
Pacific Scientific
HoneywellTempe, AZ
RaytheonTucson, AZFt. Greeley, AK
Northrop GrummanSalt Lake City, UT OATK
Magna, UT
Missile Defense
Integration and
Operations Center
(MDIOC)Colorado Springs, CO
Eagle PicherJoplin, MO
RaytheonAndover, MA
RaytheonWoburn, MA
OATKHuntsville, AL
Lockheed MartinCourtland, AL
Aerojet/ColemanOrlando, FL
HoneywellClearwater, FL
Aerojet
Raytheon
Lockheed MartinCamden, AR
West
Region
East
Region
Central
Region
Lockheed MartinMoorestown, NJ
OATKElkton, MD
Boeing
RaytheonHuntsville, AL
10
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.
MAR Regional Plan (MRP)
11
FY 16 Assessment Summary
Tier DurationDate
Completed
# of
TeamsNotes
2 3 Days 20 Nov 2015 4 54 Finding – 52 Deficiencies; 2 Observations
2 3 Days 29 Jan 2016 2 26 Findings – 24 Deficiencies; 2 Observations.
1/2 9 Days 4 Mar 2016 10130 Findings – 117 Deficiencies; 13
Observations.
1/2 5 Days 8 Apr 2016 6 51 Findings – 49 Deficiencies; 2 Observations.
2/3/
4/54 Days 17 Jun 2016 7 61 Findings – 54 Deficiencies; 7 Observations.
3 2 Days 21 Jul 2016 5 24 Findings – 23 Deficiencies; 1 Observation.
2/3 3 Days 22 Jul 2016 5 31 Findings – 26 Deficiencies; 5 Observations.
FY16 Assessment Summary
• 7 Locations
• 377 Total Findings.
• 345 Deficiencies (90%), 32 Observations (10%)
12
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
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
15
• 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
MDA-DCMA Partnering
16
• 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
“Made for MDA” Campaign
17
Recent/Upcoming MDA Program Quality/Supplier Days
Targets
Quality Day
201626 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
201657 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
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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
19
• 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
Conclusions
20