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