4 March 2008

Presented by:

Ms. Patti MartinDirector, Engineering DirectorateAviation and Missile Research,

Development, and Engineering CenterRDECOM

Presented to:16th Annual

Conference on Quality in theSpace and Defense Industries

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Quality Roles in Operations and Sustainment

Approved for public release; distribution unlimited.Review completed by AMRDEC Public Affairs Office (3/3/08 FN# 3466)

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Our World

• Legacy Systems (30+ years)• Harsh Operating Environment• Maintenance Intensive• Analog to Digital• Obsolescence• Critical Safety Items• Downsized Industrial Base

Stressed• Reliability Issues in a High

Optempo World• Maintaining Quality of Items

Produced

Challenges to Sustainment Life of Aviation & Missile Weapon Systems

• Short Design Life-10 year range• Long Actual Life-20 year range• Harsh Storage Conditions• High Optempo• Electronics Intensive• Exotic materials• Stockpile Life• Disposal• Electronics Obsolescence• Maintaining a Warm Industrial Base• Maintaining Quality of Items

Produced

AVIATION MISSILE

Strong Sustainment Elevates Operational Readiness

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Engineering Directorate Core Functions

• Acquisition Management

• Systems Engineering Management

• Test and Evaluation Management

• Production Engineering

• Product Assurance

• Technical Data

• Supportability Engineering

• Technology Development and Management

• Hardware Development, Fabrication, and Integration

• Business Management

Serving Warfighter Needs Through World Class Life Cycle Engineering and Technical Expertise

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Be Decisive!Improve Improve OurOur Support to the Soldier Support to the Soldier EveryEvery Day Day

2

Lest we forget…

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MissileNonconformance

Test failuresAround

34%

Prime not flowingDown requirements

To sub tiers

Source ApprovalProcessIssues

Dependence on Prime

(Loss of Controls)

Insufficient Process Audits

Quality Issues

Industrial Base

Capacity

Increased Dependence on Supplier

Base

Technical Data

Quality Metrics

Ineffective Incentives for

Quality

Late Deliveries, Long Lead Times – Soldier Directly Impacted !

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Importance of StrongSupply Chain

IMMC/CCAD

Prime 1 Prime 2

Prime 3Prime 4

Tier 1A

Tier 1C

Tier 1D

Tier 1E

Tier 1B

Tier 2A Tier 2B

Tier 2D Tier 2C

RawMaterial

Providers

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The Changing Faces of Quality

• Ineffective use of the Systems Engineering Process

• “Trust Me” approach to quality• Government oversight functions reduced if

not eliminated• Inadequate incentives to drive quality• Lack of detailed requirements in

performance specifications• Inadequate verification of Quality Systems

as a function of time.• Ineffective Quality Metrics• Ineffective Corrective Action Systems• Lack of focused Continuous Improvement

Programs

• First Article Tests • Comprehensive/Effective Audits• CSI Standards• Design in Sustainment processes and

procedures during design development.• Proactive Quality and Supply Chain

Management• Leverage lessons learned and best

practices observed• Commit ourselves to measurable and

enforceable results.• Exercise the leadership required to develop,

influence, and enforce manufacturing systems that adhere to the fundamentals of sound quality assurance

• “Real-Time” metrics and Information• Sharing Information collaboration across the

community.

Pre War Philosophy Lessons LearnedAs the pendulum swings…

RED-RED-RED Items: 234 at Beginning of War; Now 46

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The Sequential Enterprise

The Goal: Strengthen the Enterprise

Command

Prime

First Tier Suppliers

Depots

Second TierSuppliers

Raw Material Suppliers

Legacy Systems

OrdersDistribution

Points

Command

PrimeManufacturers

1st , 2nd And 3rd

TierSuppliers

Raw MaterialSuppliers

IntegratedCollaborative

Supply Network

Depots

Transform

Transparent Communication“Over-the-wall” Communication

Example

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The Collaborative Partnership

• Price Emphasis• Functional Silos• Short-Term Buying• High Levels of Safety Stock

• Expediting Due to Problems• Historical Information• Short Shipments

• Inefficient Use of Capacity• Withhold Information• Weakens our ability to support the

warfighter

• Lowest Total System Cost• Cross-Functional Teams• Long-Term Commitments• Compressed Cycle Times and

Reduced Inventories• Anticipating Future Capabilities• “Real-Time” Information• Reliability and Customer Service

Focus• Run Strategy & Synchronization• Sharing Information• Strong warfighter support through

strong community commitment and focus

Arms Length Relationship Collaborative Partnership

The partnership process shifts the way we view our specific relationships

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What Are We Doing About It?

• Enhancing Strong Collaboration and Communication– Joint Army, Navy, Air Force Quality Group to Address Common Concerns– Host Annual Quality Summit – Government and Industry Collaboration

• Follow up Focus Group April 2008• 2008 Summit late August

– Product Assurance Reviews between Program Offices

• Reinforcing Strong Life Cycle Quality Programs– Standardized Quality Language for Contracts based upon Lessons Learned– Product Assurance Readiness Levels (PARLs)– Formed a Cross-Functional Supply Chain IPT for a Factory to Foxhole View– Continued Mapping of Critical Supply Chain Links– Stronger Link from Quality Results to Procurement Processes– Proactive First Article Management Pilot Case

• Developing Strong Leadership and Technical Expertise– Performed Gap Analysis of Technical Expertise– Quality and Reliability Intern Program– Leadership Training!!!

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QUALITYLEADERSHIP

Vision

Proactive

Professional

DisciplineCommunication

Commitment

Understanding

Strengthening The Business of Quality

World Class Quality is a Question of Leadership

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I Challenge You to be Quality-Minded Leaders; to Influence People by Providing Purpose, Direction,

and Motivation; and to Strengthen the Organization by Focusing on Quality and Continuous

Improvement,Throughout the Life Cycle - Especially in Operations and Sustainment.

Make a Difference – the Warfighter is Relying on Us!!!

Challenge

You cannot manage people to be quality-minded,You cannot manage people to be quality-minded,you have to LEAD them to be quality-minded.you have to LEAD them to be quality-minded.

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Questions?