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Are You Getting the Most from Your Quality Engineer?
Presented by
Charles B RobinsonCertified Lead Auditor / Senior Quality Engineer
Quality Assurance & Risk Management Services, Inc.
This session is intended to provide an outline of how Quality Engineering (QE) should be adding value during the Life Cycle phases of a Project.
This session will:
Correlate the Life Cycle model with NASA Procedural Directives (NPD’s), NASA Procedural Requirements (NPR’s), AS9100, and the QE Disciplines
Explain a QE’s mission assurance contribution to processes and procedures during the project life cycle
Provide a reference tool that QE’s can use during the Life Cycle of a project.
Provide an understanding of how a project has embraced the mission assurance aspects of AS9100D from a QE's perspective
Software Disciplines are not addressed in this Session
Purpose
AS9100Life Cycle
Mission AssuranceRequirements
NPD’s & NPR’s
Competency Wheel
NASAQuality Engineers
Supportive Systems
PLAN DO CHECK ACT4
Context of Organization
5Leadership
6Planning
7Support
8Operation
9Performance Evaluation
10Improvement
No Requirements1
Scope2
Reference3
Terms & Definitions
Conduct QualityEvaluations &Data Analysis
PerformQuality Assurance
Management& Planning
Define & PerformInspection Testing& Acceptance
Activities
Conduct Procurement
QualityEngineering
Define &ImplementProduction,Material &
Process Controls
ImplementProblem Reporting& CorrectiveActions (PRACA)
AssuresAdequateDesign &
DevelopmentControls
QualityEngineer
For more detail contact:Michael P. Kelly
NASA Safety Center302-286-0662
mailto:[email protected]
NASA Life-Cycle Phases
Phase CFinal Design
& Fabrication
Phase FCloseout
Phase EOperations
& Sustainment
Phase BPreliminary Design &
Technology Completion
Phase DSystem
Assembly,Integration &
TestLaunch
Phase AConcept & Technology
Development
Pre-Phase AConcept Studies
Project Life-Cycle Phases
OR
R
FRR
PLA
R
CER
R
Key Decision Points
MC
R
SR
R
PD
R
CD
R/
PR
R SIR
TRR
DR
SA
R
PFA
R
Launch
Formulation ImplementationApproval
MCR – Mission Concept ReviewSRR – System Requirements ReviewMDR – Mission Definition ReviewSDR – System Definition ReviewPDR – Preliminary Design ReviewCDR/PRR – Critical Design Review / Production Readiness ReviewSIR – System Integration Review
TRR – Test Readiness ReviewSAR – System Acceptance ReviewORR – Operations Readiness ReviewFRR – Flight Readiness ReviewPLAR – Post Launch Assessment ReviewCERR – Critical Events Readiness ReviewPFAR – Post-Flight Assessment ReviewDR – Decommissioning Review
MD
RS
DR
NPR 7123.1NASA Systems
EngineeringProcesses and Requirements
NPR 7120.5NASA Space
Flight Program & Project Mgmt. Requirements
SRR – System Requirements ReviewTo evaluate whether the functional and performancerequirements defined for the system are responsive tothe program's requirements on the project andrepresent achievable capabilities.
The Quality Engineer understands the System Definition to assure their future activity is focused on mission success
Understand initial requirements - End Items functional baselineUnderstand clarity of system definition - architectural level of designCreate the SMA quality level requirements, e.g., develop the SMA Plan. Identify workmanship standards, critical technology, long lead items.NASA Advisories (NPR 8735.1) and GIDEP are addressed in the Safety & Mission Assurance PlanCommunicate concerns (schedule, technology, long lead items, etc.)
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Risk Management Plan (G-3.3) P/2 B/1 U/1 6.1, 8.1.1Risk Mitigation Plan (F-7.0) I/2 U/2 U/2 U/2 U/2 U/2 U/2 8.2.2Safety & Mission Assurance Plan (G-3.2) P/1 B/1 U/1 U/1 U/1 6.0Material Requirements Plan (NPR 8730.2) I/2 U/2 U/2 U/2 8.1, 8.1.4Configuration Management Plan (G-3.14) P/2 B/2 U/2 8.1.2Acquisition Plan (G-3.4) P/2 B/2 8.4Technology Development Plan (G-3.5) P/2 B/2 8.2.2.d
MissionSuccess
Environment
Ground
Suppliers
University
Workmanship
Training
Mission AssuranceStaff
Material
Length of Mission
Instruments
New Supplier
Documents
Spares
Software
Reliability
GIDEP
SOW
LOD
Durationof Mission
Components
Safety & Mission Assurance Plan
Problem / Failure Reports from similar Projects
Experienced?
SupplierHistory
Equipment
Mandatory Inspection
Points
Areas to consider to prepare for your involvement
Launch vehicle
Spacecraft
On‐Site Personnel ?
Safety
Materials
High Risk Electronic
Parts [ERAI, Inc.]
GIDEP Information
[NANADARTS]
NASA Advisories
[NANADARTS, NARS]
Customs & Border
Protection C/F Parts Seizures
[CBP]Commodity Information
[SAM]
General Supplier
Information [DLIS]
PQA “Surveyed
Supplier” Info [GRC, JSC]
Supplier Information
Surveys [Supplier Provided]
Audit Reports [NASA Audits]
Debarred Suppliers
[DLIS]
Supplier QMS Certifications[Audit Teams,
Suppliers, OASIS]
Supplier Ratings
[DCMA, Navy, SAS]
Supplier Assessment System (SAS)
NPR 8735.2, ¶2.6.3.5
SAS Administrator - [email protected] Web site - http://sas.nasa.gov/
MDR (R) – Mission Definition ReviewSDR (H) – System Definition Review
The Quality Engineer.Knowing the project's mission/system definition and associated plans,analysis the risks, identifies the resources needed for mission assurance,and starts a compliance matrix.As a component of the Verification & Validation Plan, Mandatory InspectionPoints are identified by the QE.Identifies any concerns prior to beginning Phase B.
To evaluate the credibility and responsiveness of theproposed mission/system architecture to the programrequirements and constraints, including available resources. To determinewhether the maturity of the project's mission/system definition and associatedplans are sufficient to begin Phase B.
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Risk Management Plan (G-3.3) P2 B1 U1 6.1, 8.1.1Safety & Mission Assurance Plan (G-3.2) P1 B1 U1 U1 U/1 U/1 6.0
Verification & Validation Plan (G-3.9) P2 B2 U2 U2 8.4.2, 8.4.3, 8.5.1.m
Baseline the Safety & Mission Assurance Plan (SMAP)
QEStart
GSFC ‐ 380‐WI‐7120 1 1AProject and or Program Mission Assurance Requirements (MAR) Preparation – Figure 1
PDR – Preliminary Design ReviewTo evaluate the completeness/consistency of theplanning, technical, cost, and schedule baselinesdeveloped during Formulation. To assess complianceof the preliminary design with applicable requirements and to determine if theproject is sufficiently mature to begin Phase C.
The Quality EngineerReviews the flow-down requirements to assure they are properly identifiedincluding workmanship standards, NASA Advisories/GIDEP, etc.Confirm the preliminary design is sufficiently mature to protect missionassurance, including schedule.Identify potential risk using FMEA as appropriate.Contribute to the initial Hazard Analysis
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Mishap Preparedness and Contingency Plan (NPR 8621.1) P/1 U/1 B/1 U/1 8.2.1
Safety Data Packages (NPR 8715.7) I/1 U/1 F/1 7.3, 8.1.3
ELV Payload Safety Process Deliverables (NPR 8715.7) P/1 P/1 B/1 8.1.3
Safety & Mission Assurance Plan (G-3.2) P/1 B/1 U/1 U/1 U/1 U/1 6.0
Failure Mode & Effect Analysis (FMEA) – Screening Process
FMEA
NASA, National Space Transportation System (NSTS) 22206, Req’ts. for Preparation & approval of FMEA & Critical Items List (CIL) – Figure 3-2
Goddard Space Flight Center (GSFC)-FAP-322-208-FMEA-Draft – Functional, Design, Interface, Software, GSE, and Process FMEA instructions – Figure 1-2
0%2%4%6%8%
10%12%14%16%18%
Review the Corrective Action history of the department or supplier to identify weaknesses that should be mitigated.
The above are the combined supplier audit results performed by a NASA Centerfrom 2Q2015 to 1Q2016
CDR – Critical Design ReviewPRR – Production Readiness Review
To evaluate the integrity of the project design and itsability to meet mission requirements with appropriatemargins and acceptable risk within defined project constraints, including
available resources. To determine if the design is appropriately mature tocontinue with the final design and fabrication phase.
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
The Quality Engineer.Input Mandatory Inspections as appropriateComplete the Hazard Analysis and confirm controls are in placeConfirm the Test Plan is in placeValidate the requirements for integration are in place (if applicable)
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Integration of systems P/2 U/2 4.4.1
Product Integration Process – NPR 7123.1, Figure C-7
SIR – System Integration ReviewTo evaluate the readiness of the project andassociated supporting infrastructure to begin systemAssembly Integration & Test (AI&T), evaluate whetherthe remaining project development can be completedwithin available resources, and determine if the projectis sufficiently mature to begin Phase D.
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
The Quality Engineer Review documentation prior to testing and/or integration to assure compliance.Verify compliance to the Test Plan
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Mission Operations Plan (G-3.10) P/2 B/2 U/2 6.2Rank Safety Risk Management Process Documentation (H-3.24) B/1 6.1.1, 8.1
Subject Sample of areas to review Confirmed by QEFinal Design Change Notices clearly understoodSafety Data Package Assure that mitigations are in placeFMEA Analysis complete and mitigation plans in placeDrawings Reviewed for the ability to manufacture and inspectVerification Plans Mandatory Inspection PointsPQA Supplier flow-down appropriateQA Audit Audits complete and findings satisfiedHazard Analysis Created and hazards understood / mitigatedMission Assurance Requirements
Risk Assessments addressed, As-built parts list approved…
Develop a Checklist to assure theMission Assurance areas are covered.
TRR – Test Readiness Review
Ensure that for each planned test or series of tests thetest article (hardware / software), test facility, supportpersonnel, and test procedures are ready for testingand data acquisition, reduction, and control.
A TRR for each planned test or series of tests ensures that the test article(hardware/software), test facility, support personnel, and test procedures areready for testing and data acquisition, reduction, and control.
Life Cycle Phase A B C D E F
AS9100↓ NPR 7120.5 (Sections) ↓ SRR
MDR
SDRPDR CDRPRR SIR TRR ORR FRR DR
NPR 7123.1, Table G-10, TRR Entrance & Success Criteria B/2
8.3.4.18.4.2
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
The Quality Engineer Review and/or contribute to the test proceduresIdentify Mandatory inspection points and assure they are incorporated into the test documents.Develop a plan to validate/witnessing test results (LOD for off-site, on-site SMA plan)
Documented, Accepted, Configuration Control, & Communicated
A Sample of “Things” that need to be in place.
ORR – Operations Readiness ReviewTo evaluate the readiness of the program, including itsprojects, ground systems, personnel, procedures, anduser documentation. To operate the flight system andassociated ground systems in compliance withprogram requirements and constraints during theoperations phase.
I – Initiate, P – Preliminary, B – Baseline, U – Update, F- Final -&- 1 – Develop, 2 – Research & Review Requirements
The Quality Engineer Confirm that all non-conformances have been addressed and closed.Verify that any mitigation plans have been satisfied.Validate the “as built” configuration.Confirm all GIDEP’s or NASA Advisories have been addressed.Confirm the Safety Data Package is complete.
Life Cycle Phase A B C D E FAS9100
↓ NPR 7120.5 (Sections) ↓ SRR MDRSDR PDRCDRPRR SIR TRR ORR FRR DR
Nonconforming Product I/1 U/1 U/1 U/1 8.4Mitigation Plans P/2 U/2 U/2 U/2 8.1.1.d
As-built Configuration P/1 U/1 U/1 U/1 U/1 8.1.2, 8.3.6, 8.5.2
GIDEP ALERT, SAFE-ALERT, Problem Advisory, Agency Action Notice, and NASA Advisory
Safe AlertsAlertsProblem AdvisoriesAgency Action NoticesLessons LearnedProduct Chang NoticesProduct InformationDMSMSReliability MethodologyFailure AnalysisReliability PredictionsReliability StatisticsFacilities DocumentsComputer TechnologyProcess SpecificationsTest ReportsEngineering ReportsManagement ReportsSoldering TechnologiesTechnical ManualsGeneral MetrologyCalibration Procedures
FailureExperience
ProductInformation
Reliability
Engineering
Metrology
Advisories&
An overview of GIDEP investigations throughout the Life-Cycle
NPR 1441.1E - NASA Records Management Program Requirements,Appendix D: Agency Filing Scheme
5100 – Procurement (Contracts)5300 – Reliability and Quality Assurance5700 – Safety and Mission Assurance
The Records Life-CycleNPR 1441.1, Figure 1
National Archives & Records Administration (NARA)
Presented byCharles B. Robinson
Quality Assurance & Risk Management Services, Inc. / Navarro Engineering Solutions, 22 Highridge DriveAmerican Canyon, CA 94503www.QAandRM.com / www.NavarroES.com
Email: [email protected]: +1 480.276.7649
http://www.qaandrm.com/http://www.navarroes.com/mailto:[email protected]
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