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. ICBMs – A continuing Success Story
Atlas
Thor
Titan
MM III PK
SICBM
1957
1959
1961
1964
1968
1983
1989
MM II
MM I
SLE
2000
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
In An Uncertain World ICBMs Continue To Be
Important To Our National Defense
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
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
Key Features
Benefits
Well established process to identify and qualify new vendors
Programs executed on plan with no substandard parts or components delivered to field
Focus on developing and qualifying vendors to meet our high standards before production starts
Understanding of our needs as a customer and sound basis for shared success
Monitor suppliers, during design and production, for successful corrective actions addressing variances from plan
Ensures timely awareness of difficulties and provides time to correct without impact to customer
Multi-tier vendor audits and assessments
Reinforces commitment to quality products throughout supply chain
Suppliers evaluated for ability to consistently produce quality products
Vendor oversight approach adapted to needs of supplier 1

5. Process for Supplier Management
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
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
Functional and Physical Configuration Audits
Acquisition Planning
Critical Design Review
Low Rate Production
Full Rate Production
Deliver Accepted Products
Contract/ Subcontract Awards
Weapon System Integration Testing
Production Readiness Reviews
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
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) 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. Supplier Audit IAW ISO9000/AS9100
Supplier Development
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 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. Supplier Surveillance
Surveillance Includes Periodic Audits F S
MRB
Supplier Management
Corrective Action System
Procurement System
Training Records
Metrics and Metrics Analysis
Product Identification
Configuration Management
Data Management
Internal/External QA Audit results
Tool Control
Calibration System
Production
Development
Periodic Audits
F = Frequent S = Seldom

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