DoD Standardization Conference Lansdowne, Virginia

“Aerospace Qualified Electronic Components”

Joe Chapman

Defense Standardization Program

432-697-9970

jvchapy@aol.com

March 17, 2004

Why Consider AQEC?

The Perry directive of 1994 and industry response to increased usage of COTS from components to complete systems has resulted in issues:

Component Challenges:

• Radiation susceptibility

• Short design and service life

• Uncontrolled configuration changes

• Narrow temperature ranges

Component Challenges:

• Radiation susceptibility

• Short design and service life

• Uncontrolled configuration changes

• Narrow temperature ranges

System Challenges:

• DMS - Obsolescence

• Continuous upgrades

• System-on-a-Chip

• Open Systems

System Challenges:

• DMS - Obsolescence

• Continuous upgrades

• System-on-a-Chip

• Open Systems

Our Response – The Integrated Aerospace Parts Acquisition Strategy

• Part I (in place): Electronic Component Management Program (ECMP)– Industry documents in place: IEC 62239 and EIA

4899– Avionics suppliers document their processes for

managing electronic components, in accordance with industry documents

– Plans are approved by a third party, e.g., IECQ– Avionics suppliers use approved plans as baseline

RFP processes

Our Response – The Integrated Aerospace Parts Acquisition Strategy

• Part II (in development): Aerospace Qualified Electronic Component (AQEC)

– Streamline implementation of ECMP

– AQEC parts are automatically approved per IEC62239 and EIA 4899

– Use AQEC parts “as-is”

Industry Consensus Definition:

Aerospace Qualified Electronic Component The intent of this definition of an Aerospace Qualified Electronic Component (AQEC) is to (a) ensure that electronic

components used in aerospace applications are reliable in those applications; (b) provide aerospace access to component manufacturers’ commercial-off-the-shelf (COTS) products at acceptable cost; (c) minimize deviations from the component manufacturers’ COTS products; (d) have little or no negative impact on the AQEC suppliers’ operating or business procedures; and (e) promote communication between the component manufacturer and the aerospace users.

1. The AQEC should have the following features:– Designed, fabricated, assembled, and tested in accordance with the component manufacturers’

requirements for (COTS) products;– Qualified in accordance with the component manufacturer’s standards and specifications for the

manufacturer’s COTS products;– Subject to the component manufacturer’s design, manufacturing, quality assurance, and quality

systems standards, technical specifications, procedures, and other similar requirements for COTS products.

2. In order to be considered an AQEC, the component manufacturer’s COTS component should undergo testing and/or analysis to assess its reliability in the aerospace application. The process to do so should be mutually agreed upon by the AQEC suppliers and users.

3. The configuration of the device should remain stable for a specified period of time. (This may be done in a variety of ways, but one example would be to characterize given lots of devices as AQEC, in sufficient quantities to supply the aerospace market for agreed-upon periods of time.)

The intent of this definition of an Aerospace Qualified Electronic Component (AQEC) is to (a) ensure that electronic components used in aerospace applications are reliable in those applications; (b) provide aerospace access to component manufacturers’ commercial-off-the-shelf (COTS) products at acceptable cost; (c) minimize deviations from the component manufacturers’ COTS products; (d) have little or no negative impact on the AQEC suppliers’ operating or business procedures; and (e) promote communication between the component manufacturer and the aerospace users.

1. The AQEC should have the following features:– Designed, fabricated, assembled, and tested in accordance with the component manufacturers’

requirements for (COTS) products;– Qualified in accordance with the component manufacturer’s standards and specifications for the

manufacturer’s COTS products;– Subject to the component manufacturer’s design, manufacturing, quality assurance, and quality

systems standards, technical specifications, procedures, and other similar requirements for COTS products.

2. In order to be considered an AQEC, the component manufacturer’s COTS component should undergo testing and/or analysis to assess its reliability in the aerospace application. The process to do so should be mutually agreed upon by the AQEC suppliers and users.

3. The configuration of the device should remain stable for a specified period of time. (This may be done in a variety of ways, but one example would be to characterize given lots of devices as AQEC, in sufficient quantities to supply the aerospace market for agreed-upon periods of time.)

Industry Consensus Definition:

Aerospace Qualified Electronic Component

Intent of Aerospace Qualified Electronic Component (AQEC) definition:(a) Ensure that electronic components used in aerospace applications are reliable in those applications (b) Provide aerospace access to component manufacturers’ commercial-off-the-shelf (COTS) products at acceptable cost (c) Minimize deviations from the component manufacturers’ COTS products (d) Have little or no negative impact on the AQEC suppliers’ operating or business procedures (e) Promote communication between the component manufacturer and the aerospace users

Intent of Aerospace Qualified Electronic Component (AQEC) definition:(a) Ensure that electronic components used in aerospace applications are reliable in those applications (b) Provide aerospace access to component manufacturers’ commercial-off-the-shelf (COTS) products at acceptable cost (c) Minimize deviations from the component manufacturers’ COTS products (d) Have little or no negative impact on the AQEC suppliers’ operating or business procedures (e) Promote communication between the component manufacturer and the aerospace users

Industry Consensus Definition (continued):

Aerospace Qualified Electronic Component

1. The AQEC should have the following features:–Designed, fabricated, assembled, and tested in

accordance with the component manufacturers’ requirements for (COTS) products;

–Qualified in accordance with the component manufacturer’s standards and specifications for the manufacturer’s COTS products;

–Subject to the component manufacturer’s design, manufacturing, quality assurance, and quality systems standards, technical specifications, procedures, and other similar requirements for COTS products.

1. The AQEC should have the following features:–Designed, fabricated, assembled, and tested in

accordance with the component manufacturers’ requirements for (COTS) products;

–Qualified in accordance with the component manufacturer’s standards and specifications for the manufacturer’s COTS products;

–Subject to the component manufacturer’s design, manufacturing, quality assurance, and quality systems standards, technical specifications, procedures, and other similar requirements for COTS products.

Industry Consensus Definition (continued):

Aerospace Qualified Electronic Component

2.In order to be considered an AQEC, the component manufacturer’s COTS component should undergo testing and / or analysis to assess its reliability in the aerospace application. The process to do so should be mutually agreed upon by the AQEC suppliers and users.

3.The configuration of the device should remain stable for a specified period of time. (This may be done in a variety of ways, but one example would be to characterize given lots of devices as AQEC, in sufficient quantities to supply the aerospace market for agreed-upon periods of time.)

2.In order to be considered an AQEC, the component manufacturer’s COTS component should undergo testing and / or analysis to assess its reliability in the aerospace application. The process to do so should be mutually agreed upon by the AQEC suppliers and users.

3.The configuration of the device should remain stable for a specified period of time. (This may be done in a variety of ways, but one example would be to characterize given lots of devices as AQEC, in sufficient quantities to supply the aerospace market for agreed-upon periods of time.)

AQEC Benefits

• Promotes communication between semiconductor device and aerospace industry

• Minimizes & reduces need for uprating or upscreening

• Part performance characterized for avionics

• Component Roadmap / Transition Plan – DMSMS

• Minimize / Reduce LTB and ‘tactical’ reaction….

• Assures configuration control – “Better Manage DMSMS”

• Assures part availability – “Better Manage DMSMS”

• Enables system design tradeoffs (performance, lifetime, supply voltage, speed, temperature, etc.)

• Enables ‘higher-level’ system options, e.g., system-on-a-chip, throw-away cards

We don’t have to re-create the mil-spec system

The AQEC Process Flow

Semiconductor device mfr

Aerospace user

Inventory manager

Joint activityAssessment body

Characterize AQEC parts

Define “essential aerospace

care-abouts”

Forecast part volumes

AQEC definition

Part/family specifications

Approve processes

Purchase & inventory

AQEC parts

Use AQEC parts

Document AQEC characterization

processes

Parsimonious list of

parts/families

Feedback

Why does this have potential for success?O Many such components already exist and are in aerospace

applications

O Texas Instruments & National Semiconductor introduced specific product families targeted for such applications –

“Enhanced Plastic”

O IC manufacturers realize it takes all stakeholders to meet the challenge ahead & legalism alone will not spare anyone

O Modern ICs have incredible capability yet many risks remain – especially if inappropriately used

O It “is” about money and profits and motivation exists……

O Collaboration across the related industries has been excellent!

The Question remains-Do we have the will to succeed?

Recent progress:

O Avionics Process Management Committee (APMC): with semiconductor industry developed an AQEC “Definition”

O G-12 and JEDEC committees met with APMC in Phoenix in January and have established a working group to define next steps

O Semiconductor companies (2-3) joining APMC

O NAVAIR – PAX River has supported AQEC effort for past 1 ½ yrs

O “Socialization” of this effort continues….ADUSD (LPP) briefed in December 03 and received support

O JACG briefed in January 04 and further support granted

O FAA and NASA participating in meetings and seeking ways toutilize AQEC components where appropriate

O AIA Product Support and Engineering Management Committee briefed and received support

Who’s InvolvedDoD:

NAVAIR, DSPO, AWACS, AMCOM, JCAA, DUSD(L&MR)

DoD:

NAVAIR, DSPO, AWACS, AMCOM, JCAA, DUSD(L&MR)

Airframe Integrators:

Boeing, Lockheed Martin, Northrop Grumman

Airframe Integrators:

Boeing, Lockheed Martin, Northrop Grumman

Avionics OEMs:

Honeywell, BAE, Smiths, Rockwell Collins, Goodrich

Avionics OEMs:

Honeywell, BAE, Smiths, Rockwell Collins, Goodrich

Part Manufacturers:

Motorola, AMI, Micron, Texas Instruments, IBM, Intel, Xilinx, National, LSI Logic, Vishay-Siliconix, Linear Technology, Altera, Philips, Analog Devices

Part Manufacturers:

Motorola, AMI, Micron, Texas Instruments, IBM, Intel, Xilinx, National, LSI Logic, Vishay-Siliconix, Linear Technology, Altera, Philips, Analog Devices

Others:

NASA, FAA, COG, G-12, EIA, SIA, JEDEC, AIA, AVSI, DSCC

Others:

NASA, FAA, COG, G-12, EIA, SIA, JEDEC, AIA, AVSI, DSCC

What do we need to do next?O Continue the ‘socialization’ efforts –– industry / government

O Activate the AQEC working group and begin work

O Customers (DoD – FAA – NASA – airframe integrators): Issue Customers (DoD – FAA – NASA – airframe integrators): Issue “mandate” to use AQEC in critical applications, e.g., “mandate” to use AQEC in critical applications, e.g.,

contract flow-down-contract flow-down-------------”REQUIRED BY Air ------------”REQUIRED BY Air Framers/NASA/FAA?”Framers/NASA/FAA?”

O O System designers: Use AQEC where required – no exceptionsSystem designers: Use AQEC where required – no exceptions

O Semiconductor device manufacturers: Develop and apply O Semiconductor device manufacturers: Develop and apply AQEC processesAQEC processes

O If necessary, change the rules---O If necessary, change the rules---Socialization / Collaboration & Socialization / Collaboration & might require legislationmight require legislation

Utilize DoD Standardization Program Office where appropriate!Utilize DoD Standardization Program Office where appropriate!

Points of Contact for AQEC information:

Joe Chapman Lloyd Condra

jvchapy@aol.com lloyd.w.condra@Boeing.com

432-697-9970 206-655-8240