Integrating Industry Standards Through Early Action and Risk...
Transcript of Integrating Industry Standards Through Early Action and Risk...
Integrating Industry Standards Through Early
Action and Risk-Based Tailoring
Sherri Fike
March 2012
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Ball has Taken the Industry Challenge
Abstract: “Reduce risks and increase compliance to new requirements while
increasing efficiency”
Challenge: Define and execute efficient processes and tools that meet a wide range
of program contractual requirements and risk profiles
Solution: 1) Active participation on standards development teams
2) Early Adopters of new standards and processes
3) Deploy comprehensive process tailoring approach
High Value National Assets Research and Development
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Ball Actively Participates
On Industry Standard Development Teams
Counterfeit Parts • >75 companies & govt agencies
• 1 std published, many near release
• Influenced 3rd party cert structure,
independent distribution risk mitigation
AAQG
• Voting Member on ~20 AS stds
• Influenced QMS certification
scheme and auditor training
• Gained early interpretations of
AS9100C and AS9101D
MAIW
• On Steering Comm & 4 WGs
• >20 companies & govt
participants
• Influenced future TORs, early
adaption and insight
NADCAP • On Nadcap Management Council
and four commodity task
• Vote on procs, checklists, audits
• Influenced space electronics
checklist used for Nadcap cert
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Ball Focuses on Early Adoption of Standards
Lifting Devices and Equipment
• FMECA on 35 critical handling pieces of
equipment
QMS & Audit Requirements
Early involvement Planned
Approach
&
Training
Learned with experts
Lead Essential
Change
All Levels, many forums Performed Internal
Assessments
Management Review
2008
Managed the
Assessment
2010
2011
2009
2009
2011
NASA-STD-8719.9
• Project satisfied other regulatory
requirements such as OSHA , ANSI,
CMAA, etc.
AS9100C and AS9101D
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Industry Mission Risk Profile Established
Framework provided by
─DoD Hdbk 343, NASA NPR 8705.4
─Mission Risk Planning and Acquisition
Tailoring Guidelines for Natl Security
Space Vehicles 2010 (TOR-2011(8591)-5)
─MA Guidelines for A-D Mission Risk
Classes 2011 (TOR-2011(8591)-21)
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Ball Product Class Foundation
Class 1 Class 2 Class 3 Class 4 Class 5
Space Mission
Risk Class Risk Class A Risk Class A/B Risk Class C/D Ground Systems
Risk Acceptance
for Product
Minimum Practical
Risk Low Risk Moderate Risk Higher Risk N/A
Rig
or /
Cos
t
Purpose of Product Classes
─Define minimum requirements for product development
in advance of Process Tailoring
─Gain efficiencies by taming “infinite agility”
Codified by
• MA & Eng Process Definitions
• Material channel requirements
• Manufacturing requirements
• Tribal knowledge
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Product Class Std Describes Major Disciplines
Product Class Risk
Considerations
Product
Class 1
Product
Class 2
Product
Class 3
Product
Class 4
Product
Class 5
Risk
Acceptance
for Product
Minimum practical risk Low risk Moderate Risk Higher Risk N/A
Mission
Assurance
Comprehensive MA
and customer
insight / oversight
MA focused on
risk avoidance and
risk tolerance
MA limited to high risk
areas and controlling
the level of uncertainty
MA limited to critical
interfaces
No MA
Engineering Comprehensive
requirements flow
down and design
analysis;
Customer insight and
review at detail level
Formal design and
review practices
Responsible engineer
designs with peer
oversight and optional
formality
Specific engineering
analysis or certification
required only in some
areas
No design
requirements
Material Product Class 1-2 Parts and Inventory
Full Pedigree
Product Structure defined BOM
Requisition and Purchase Order only
Class 3 Parts and Inv.
Limited Pedigree
Product Structure
Req. and PO only
Class 4 Parts and Inv.
No Pedigree
Product Structure
P-Card option
Limited part rqmts.
No Pedigree
Misc. Material option
P-Card option
C&DM Production Release required
Limited Release
option
No release
requirements
Manufacturing Build Documentation required Build Documentation required
only in scheduled work centers
Product
Examples
Critical operational
space systems
Human-rated space
systems
Commercial space
instruments, buses,
and components
Tactical Systems
Secondary space
instruments, buses,
and components
High-fidelity EDUs **
STE and GSE
EDUs **
STE and GSE
Tooling
Prototypes
Models and mock-ups
Shop aides
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What Does “Tailored Program Solution” Mean?
Program Planning = Agility to Innovate
Proven Standards = Strength to Deliver
Customer
Specs &
Standards
Risk
Contract,
SOW
Customer
Requirements
Customer Expectations &
Requirements Mission
Class
Experience
& Expertise Lessons
Learned
Best
Practice Legal &
Regulatory
Compliance
Ball Aerospace Business
Practices
Standards, Policies, Work Instructions,
Guidelines, Handbooks, BPSs, Templates…
Processes
Product Class
Selections
Tailored
Program
Solution
LCGM Profile
Selection BPL Tailoring
and Deviations
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Life Cycle Gated Milestones (LCGM) Profile Selection Builds
on Driving Customer Requirements
LCGM Profile Selection
Tailored LCGM Program Plan
Tailored Program Execution
Customer Requirements
• Performance Requirements • MA Requirements • System Architecture • Risk Posture • Cost • Schedule
Product Class
Selections
Tailored
Program
Solution
LCGM Profile
Selection BPL Tailoring
and Deviations
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A B C D
1 ANOMALY REPORT A A A A
2 SYSTEMS SAFETY PROGRAM PLAN A A A A
3 HAZARDOUS PROCEDURES FOR PAYLOAD I&T A A A A
4 SAFETY REQUIREMENTS COMPLIANCE CHECKLIST A A A A
5 PRELIMINARY HAZARD ANALYSIS R R R R
6 OPERATIONS HAZARD ANALYSIS R R R R
7 OPERATING AND SUPPORT HAZARD ANALYSIS R R R R
8 INSTRUMENT SAFETY ASSESSMENT REPORT OR MISSILE SYSTEM PRELAUNCH SAFETY PACKAGE R R R R
9 VERIFICATION TRACING LOG R R R R
.
.
.
23 PROBABILISTIC RISK ASSESSMENT TE A TE TE
24 FAILURE MODE AND EFFECTS ANALYSIS AND CRITICAL ITEMS LIST TE A TE TE
25 FAULT TREE ANALYSIS A A A TE
.
.
.
41 MATERIALS USAGE AGREEMENT A A A TE
42 MATERIALS IDENTIFICATION AND USAGE LIST A A A TE
43 NONDESTRUCTIVE EVALUATION PLAN A A A TE
Proposals Start Tailoring of Deliverables
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Product Class Selection Drives Some Differentiated Processes
Product Class Std & Guides Product Class Decisions Customer
Requirements
• Performance Requirements • MA Requirements • System Architecture • Risk Posture • Cost • Schedule WI0000092 - Product Class Selection
Program Specific Product List and associated Product Class
Tailored Program Execution
Product Class
Selections
Tailored
Program
Solution
LCGM Profile
Selection BPL Tailoring
and Deviations
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Program BPL Tailoring and Deviations are Recorded
Master Process Definitions
Product Class Decisions
Tailored Program Execution
Customer Requirements
+
SW, FPGA, SWQA, SI&T, MA, & HQI
Program Unique, Controlled
Process Definitions and PTDR
Program Profile
+
Product Class
Selections
Tailored
Program
Solution
LCGM Profile
Selection BPL Tailoring
and Deviations
Program Tailoring
and Deviation Record
+
+
Business Process Library
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Process Area Program Lead Process POC Description Justification Process POC Concurrence
Ball Aerospace (Enterprise)
Dan Miller Florence
Porter WI0000092 - PRODUCT
CLASS SELECTION
.
.
.
Cryogenics and Thermal Engineering
Brian Carter Jeff Lasco
WICTE.4.1.003 - THERMAL DESIGN, VERIFICATION AND
VALIDATION
Only snapshots of the model are saved to the PDM system (usually corresponding to customer deliverables or gate reviews). Like all other CAD systems, the active models reside on program servers. PCR 5153, when completed, will eliminate deviation
Jason Thomas
Electrical Engineering
Mark Schlueter Melanie
Ryan GLEL.4.1.001 - POWER SUPPLY SPECIFICATION
"Shall" and "must" statements will be treated as best practices. PCR 5195, when completed, will eliminate deviation
Melanie Ryan
.
.
.
Process Tailoring and Deviation Record (PTDR) Provides Roadmap
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Process Tailoring Occurs During Program Planning
En
d o
f Ta
ilori
ng
Shop Orders
Tailoring Control
BPL Program Tailoring and
Deviation Record
(PTDR)
Discipline Specific
Process Definitions (PD)
Engineering Design
Engineering Drawings
1234567
Rev A (2009-11-18)
Product
Drawing
Number
(Optional)
Product
ClassRationale
Flight Bus IIA Meets the definition of Class IIA product.
Flight Instrument IIA Meets the definition of Class IIA product.
Instrument Emulator/Mass Model III High Fidelity Model used to simulate Flight Instrument. Will interface with Class IIA - meets the definition of Class III.
Instrument Handling Fixture III Will eventually interface with Class IIA, it meets the definition of Class III. It will be certified before use.
Instrument Vibration Test Fixture III Will eventually interface with Class IIA, it meets the definition of Class III. It will be certified before use.
Optical Bench EDU III
Aligns with definition of Class IV - however, since this includes a significant sub-contract and represents "Path to Flight", it
will be developed as Class III to ensure production release documentation is subject to CCB process that affects critical
ICD level requirements.
Calibration Test Set III Used to calibrate Flight Instrument - meets the definition of Class III. It will be certified before use.
Focus Mechanism EDU IV EDU will not interface with Class IIA - it aligns with the defintion of Class IV.
Filter Wheel EDU IV EDU will not interface with Class IIA - it aligns with the defintion of Class IV.
Analysis Package IV No direct interface to Flight Bus - used to analyze test data - deliverable to customer.
Proof of Concept Circuit Design V Engineering test represents a small portion of overall PWA circuitry.
Filter Wheel EDU Shop Aid V Technician built to aid in alignment of Class IV EDU - it aligns with the definition of Class V.
Product Classification Assignments for
Program X
Product Class Selections
LGCM Profile Selection
Product Class Guides EEE Parts and Radiation Effects Engineering
Activity
Class I Class IIA Class IIB Class III Class IV Class V
Part Selection Yes No No No
Screening Program Yes No No No
Part Qualification Yes No No No
Precap Inspections Yes No No No
Destructive Physical Analysis Optional No No No
Standard Part Drawings Yes Yes Yes Optional
Part History Evaluation Yes Optional No No
Program Parts Control Board Yes Optional No No
Program Approved Parts List Yes Optional No No
Global Part Substitution Optional Yes Yes Yes
Program Part Substitution if permitted by contract documents No No No No
Part Age and Storage Restrictions Yes Yes1 Yes1 No
Part Obsolescence Yes No No No
Prohibited Items Yes Yes Yes No
Participation in Reviews Yes No No No
Part Failure Analysis Yes No No No
Radiation Analysis Yes No No No
Radiation Testing Yes No No No
Supplier Oversight and Control Yes No No No
Commercial-of-the-shelf Assemblies if permitted by contract documents Yes No No No1By part type
Rigor Values
Controlled Design &
Controlled Procurement
with specific BPL Tailoring
Controlled Build
Documents
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BATC’s Tailoring Approach Provides Flexibility and
Agility to Meet Mission Success
Our current business climate demands a broad application of
requirements, standards and processes
Risk profile, cost and schedule are primary drivers for missions
Focused participation in standards development and early adoption leads
to successful integration of industry standards
Product Classes and Tailoring provide for flexible program baselines to
meet unique mission needs
Establishing tailored program baselines should begin with Proposals
BATC’s tailoring approach provides for
rigorous program planning and execution