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.

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• 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

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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)

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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

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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

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• 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

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• 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

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• 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

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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

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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)

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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%)

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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

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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

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• 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

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• 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

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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

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• 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

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