SETP May 6, 2010 Mark Fattal Program Quality/CM A Configuration Management System for Prototype Programs Approved for Public Release: Northrop Grumman

SETPMay 6, 2010

Mark FattalProgram Quality/CM

A Configuration Management System

for Prototype Programs

Approved for Public Release: Northrop Grumman Aerospace Systems Case 10-0617 Dated 5/5/10

Agenda

• History

• General Requirements

• CM Overview

• Engineering Release Authority

• Drawing Tree

• Hardware Software Compatibility Matrix

• Configuration Release

• Prep Items

• Summary

• Question


History

• NGC Purchased a Gulfstream II in 2006

• GII Goal: – To provide a multipurpose manned aircraft to be used as a flying

test bed platform to support prototype activity, engineering concepts, program risk reduction and Headstart activity.

• Independent CM Plan:– Drafted and released in March 2007 to provide configuration of the

GII Flying Test Bed (FTB) aircraft for rapid development/prototype program using the GII flight test platform.


GII Flying Test Bed


Interior Configuration Example


General Requirements

• Program Quality Assigned Local Control– On Site Flight Test Quality Engineering Performs in a dual role as

Quality Engineer and Configuration Management.

• Engineering Release Authority with Local Tracking Number Assigned– Tracking number based upon current program.

• Quality Maintains Originals as Aircraft Records – Hardcopy Originals – Electronic Archived


CM Plan Overview

• Configuration Management Plan – Defines the Process for the Control and Release Authority for

• Drawings• Specifications • Tests• Instrumentation• Special Support Equipment• HSCM (Hardware Software Compatibility Matrix)• Flight Release EO

• All Released Documents Carry a Unique Identifier Applicable to a Specific Program (5TH Character in Drawing number)– Example

• GII50EXXXX1: Released for an Electrical Drawing for program ABC

• GII51EXXXX2: Released for an Electrical Drawing for program XYZ


FTB Drawing Tree

Flight Test Bed Drawing Tree

Supplier to NGC

InstallationDrawing

Supplier to NGC Phase 1

Installation Drawing

A/V Support Equipment

Instrum Support

Equipment

Attachment A - FTB Drawing Tree

Supplier to NGC Phase 2


SupplierMaster

Drawing List

Supplier ABC Phase 1 Master Drawing List

Supplier ABC Phase 2 Master

Drawing List

FTB Hardware/Software

Compatibility

FTB InstallationDrawing

A/V Detail

A/V Electrical

A/V Procedure

Instrum Installation

A/V Installation

Instrum Detail

Instrum Electrical

Instrum Procedure

Instrum Assembly

NGC Test Procedure

NGC Specifications

NGC Flight Config Release

Supplier to NGC ATDC Installation

Drawing

Supplier XYZ Master

Drawing List

KEY:The 5th character of the drawing number designates program specific releases, with the exception of the top tree drawing, GII50A0001.Examples of programs:0 = ABC1 = XYZ See Attachment “B” for listing

Example: GII50B0001 is a ABC program drawing, and GII51B001 is an XYZ drawing.

NGC IRAD to A/C


IRAD Master Drawing List

A/V Assembly


CM Plan Overview

• On Site Program Quality Rep is Responsible to Generate the HSCM (Hardware Software Compatibility Matrix)

• The Plan Allows for Multiple Configurations/Programs Simultaneously.

• Supports Either Engineering Generated Locally or Program Engineering provided for Incorporation Per Plan and Drawing Tree

• The Plan Outlines the Review/Release Requirement for Every Engineering Document Type Identified in Drawing Tree.


CM Plan Approved Streamlined ApproachRELEASE AUTHORITY (RA)

CAGE CODE

78022 1. RELEASE AUTHORITY NO.

2. RA REV.

3. LIAISON RA

YES NO 4. RELATED RA

5. RELEASE AUTHORITY TYPES

ERN DCN ECO DVA 6. NETWORK NUMBER

7. SHEET

1 of 1

8. STOP/LIFT ORDER

STOP LIFT PARTIAL LIFT

ESTIMATED LIFT DATE / /

9. CHANGE AUTHORITY

PCR PCR PCR PCR

10. CHANGE CLASS

CLASS I

CLASS II

11. REASON CODE

12. ECOS / RC/I INCORPORATED BY THIS DCN

13. RETROFIT/FIELD DOC REQUIRED

RETROFIT TCTO TO

14. TEMPORARY CONFIGURATION MODIFICATION

T2 MOD

15. DESCRIPTION OR REASON FOR CHANGE

16. MFG. PLANNING

YES NO

17. DF NO

18.

EFFECT SCHED

19. MODEL CODE

20. ENGINEERING EFFECTIVITY

CI NO SERIALIZATION RANGE

23. MANUFACTURING EFFECTIVITY

21. ENGINEERING CHANGE PROPOSAL APPLICABLE

ECP NUMBER 22. DEVIATION APPLICABLE

DEVIATION NUMBER

24. DOCUMENT/DWG NO

25. DOCUMENT/DWG TITLE

26. DOC/DWG REV

27. PL REV

28. NEXT ASSY PART NO (FOR REFERENCE ONLY)

29. NEXT ASSEMBLY FOLLOW-UP RA

YES ENTER SCHEDULED RA NO

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NOMENCLATURE / DESCRIPTION CUT STOCK SIZE

RAW MATERIAL

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30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.

47. ADDITIONAL DETAILED INSTRUCTIONS (FOR PARTS DISPOSITION, MANUFACTURING OR PROCUREMENT INSTRUCTIONS SUCH AS FOR REWORK, SPARES, AMRS, ETC)

48. RELEASE AUTHORITY SIGNATURES

ORIGINATOR

DATE

/ / MATERIAL AND PROCESSES

DATE

/ / STRESS

DATE

/ / PROGRAM INTEGRATION

DATE

/ / DESIGN LEAD/MANAGER

DATE

/ / PROGRAM PLANNING

DATE

/ / PRODUCT ASSURANCE

DATE

/ / PROGRAM MANAGEMENT

DATE

/ / CHECK

DATE

/ / PRODUCT SUPPORT/ILS

DATE

/ / SAFETY

DATE

/ / SOFTWARE CONFIGURATION MGMT

DATE

/ / CHIEF ENGINEER

DATE

/ / MANUFACTURING ENGINEERING

DATE

/ / RELIABILITY

DATE

/ / SOFTWARE QUALITY ASSURANCE

DATE

/ / MASS PROPERTIES

DATE

/ / MEC

DATE

/ / MATERIEL

DATE

/ / RESPONSIBLE ORG TEST MGR

DATE

/ / SYS ENG/REQUIREMENTS MGMT

DATE

/ / BUSINESS MANAGEMENT

DATE

/ / PRODUCT TEST

DATE

/ / DATA MANAGEMENT

DATE

/ / DADT

DATE

/ / OTHER

DATE

/ / OTHER

DATE

/ / CONFIGURATION RELEASE

DATE

/ / CLICK HERE FOR FORM INSTRUCTIONS


Takeoff


Hardware Software Compatibility Matrix

• HSCM (Hardware Software Compatibility Matrix)– Program Quality is responsible for the generating and maintaining

this Matrix.– The approved/released authorizes the applicable

hardware/software configuration– Archived Matrix’s maintain the configuration history to ensure the

ability to return to a prior flight test configuration or verify the as flown condition.


Example HSCM (Notional)

LRU Manufacture Part No.SW

VersionFJT/Qual

Responsible Eng. Notes

Sensor World 2514-A2103 7.1v1.10 FJT Tom Smith 2/16/2010

Transponder Waves 500107-103 1.1.2a FJT Shirley JonesSW 6500-118-402

v1.1.2a

Mass Storage Store Blade RAID GII 103.01 FJT Larry Chase dtd 2/2/10

UHF/VHF Antenna Systems 4511-310 N/A FJT Jen Swift

GPS Antenna Systems 4545-100 N/A FJT David Sandy

Switch Cisco CISCO 3750G-24TS N/A FJT Mike Lumper


HSCM Engineering Release

E1-F037 (9-07)

RELEASE AUTHORITY (RA)

CAGE CODE


RA-IRAD-026 2. RA REV.

I/R 3. LIAISON RA

X YES NO 4. RELATED RA

n/a 5. RELEASE AUTHORITY TYPES

X ERN DCN ECO DVA 6. NETWORK NUMBER

7. SHEET

1 of 1

8. STOP/LIFT ORDER



9. CHANGE AUTHORITY

PCR PCR

PCR PCR

10. CHANGE CLASS

CLASS I

CLASS II

11. REASON CODE

N/A



RETROFIT TCTO TO


T2 MOD


THE ATTACHED EXCEL SPREADSHEET IS USED TO CONTROL THE CONFIGURATION/COMPATIBILITY ALONG WITH TRACKING FJT/QUAL STATUS OF BOTH HARDWARE/SOFTWARE TO BE TESTED ON THE GII FTB DURING IRAD HEAD-START TESTING. SW VERSION UPDATE LRU 1

16. MFG. PLANNING

YES NO

17. DF NO

18.

EFFECT SCHED

19. MODEL CODE





ECP NUMBER n/a 22. DEVIATION APPLICABLE

DEVIATION NUMBER n/a

24. DOCUMENT/DWG NO

GII50HWSWCM-0015 25. DOCUMENT/DWG TITLE

FTB HARDWARE/SOFTWARE COMPATIBILTY MATRIX 26. DOC/DWG REV

15 27. PL REV

n/a 28. NEXT ASSY PART NO (FOR REFERENCE ONLY)

GII50A0001 29. NEXT ASSEMBLY FOLLOW-UP RA

YES ENTER SCHEDULED RA NO

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ORIGINATOR

M. FATTAL DATE

4/30/10 MATERIAL AND PROCESSES

DATE

/ / STRESS

DATE


DATE


DATE / /

PROGRAM PLANNING

DATE


DATE

PROGRAM MANAGEMENT

DATE

/ / CHECK

DATE / /

PRODUCT SUPPORT/ILS

DATE

/ / SAFETY

DATE

/ / SOFTWARE CONFIGURATION MGMT

DATE

/ / CHIEF ENGINEER

DATE / /

MANUFACTURING ENGINEERING

DATE

/ / RELIABILITY

DATE


DATE

/ / MASS PROPERTIES

DATE

/ / MEC

DATE

/ / MATERIEL

DATE


DATE


DATE


DATE

/ / PRODUCT TEST

DATE

/ / DATA MANAGEMENT

DATE

/ / DADT

DATE

/ / PROGRAM MANAGER

DATE

4/30/10 OTHER

DATE


M. FATTAL DATE / /

CLICK HERE FOR FORM INSTRUCTIONS Approved for Public Release: Northrop Grumman Aerospace Systems Case 10-0617 Dated 5/5/10

HWSW - Notional Sub Tier Software

Processor NGC N030300G01 NGC1234567

GII_FLT_1.0 2/14/07

IAW Flight Certification Report

- 15-DEC 2009John Henry

Avionics Processor (AI) 4.1.5

Data processor (DP)

Signal Processor ISR

Signal Processor OFP 1.0.1

Output Processor (OP)


FJT/Qualification

• FJT (Flight Justification Testing)– Responsible Engineer (RE) generates FJT/Qual sheet – Every LRU (Line Replaceable Unit)/Test Critical Component is

reviewed a by the RE and approved by System Safety for operation in expected flight envelope.


FJT/Qual Sheet

QUALIFICATION CERTIFICATE CERTIFICATE NO.

SPEC. & DASH NO.

DATE

TITLE

SUPPLIER

Mission Ops

SUPPLIER PART NO.

see above title block

BUYER

NGC

THIS ITEM SUCCESSFULLY COMPLETED THE TEST SPECIFIED IN THE INDIVIDUAL EQUIPMENT SUBJECT SPECIFICATION,

AND FULFILLS THE QUALIFICATION REQUIREMENTS FOR: FJT FQ

QUALIFIED BY QUALIFIED BY ANALYSIS SIMILARITY

QUALIFIED BY TEST QUALIFIED BY TEST/ SIMILARITY

DATA CERTIFIED

BY TEST OR BY ANALYSIS

QUALIFIED BY ANALYSIS/SIMILARITY

ACTUAL TEST COMPLETION DATE 08/20098

REPORT APPROVAL DATE 11/2009

QUALIFIED BY SIMILARITY TO

SUPPLIER REPORT NUMBERS .

D/W YES NO LIMITATIONS YES NO

DISPOSITION

DISPOSITION

Within the context of the requirements, implied or otherwise, of the G2 test program, there are no limitations with regard to flight worthiness and safety. Performance profiles and possible performance limitations do exists, but have no bearing on flight safety or flight intergrity.

FLIGHT WORTHY

THIS ITEM HAS NOT SUCCESSFULLY COMPLETED THE TEST SPECIFIED IN THE INDIVIDUAL EQUIPMENT SPECIFICATION. HOWEVER, IT IS DEEMED FLIGHT WORTHY FOR THE REASON(S) BELOW:

RISK ANALYSIS Low risk. This set of COTS hardware has been subjected to representitive flight variables during other flight activities. This equipment produced no risks to flight activities and remained stable during all flights.

EMBEDDED FIRMWARE VERSION: SYSTEM SAFETY

DATE

TEST REPORT NO.

TEST RPT APPROVAL DATE

RESPONSIBLE ENGINEER/EMPLOYEE NO.

DATE

S/W CONFIGURATION MGMT (IF APPLICABLE)

DATE

ELECTROMAGNETIC EFFECTS & NUCLEAR HARDNESS

DATE

H/W CONFIGURATION MGMT

DATE

S/W INTEGRATION (IF APPLICABLE)

DATE

CM BASELINE CONTROL

DATE

DEFINITIONS

FLIGHT JUSTIFICATION TEST (FJT) - COMPONENT HAS SUCESSFULLY COMPLETED MINIMUM NUMBER OF QUALIFICATION TESTS REQUIRED TO BE CONSIDERED SAFE FOR OPERATION DURING FLIGHT.

FULL QUALIFICTION (FQ) - COMPONENT HAS SUCESSFULLY COMPLETED SPECIFICATION QUALIFICATION TESTS.

FLIGHT WORTHY (FW) - COMPONENT IS NOT QUALIFIED FOR FUNCTIONAL USE DURING FLIGHT.

DSF-1820 (11-2000)* Approved for Public Release: Northrop Grumman Aerospace Systems Case 10-0617 Dated 5/5/10

Approved Program Configuration Release

• Engineering Release Authority That Captures at a Top Level Modification/Configuration Changes to the A/C since last flight– Top level project/program release.– Signatures required dictated by plan and some optional dependent

on TRR/FRR actions.• Stress • System Safety

• Rev Letter Continues on Subsequent Release’s Thereby, Maintaining/Tacking Multiple Configuration Simultaneously.


Configuration Release Notional

RELEASE AUTHORITY (RA)

CAGE CODE


RA-IRAD-031 2. RA REV.

I/R 3. LIAISON RA

YES X NO 4. RELATED RA

n/a 5. RELEASE AUTHORITY TYPES

ERN DCN X ECO DVA 6. NETWORK NUMBER

NA 7. SHEET

1 of 1

8. STOP/LIFT ORDER



9. CHANGE AUTHORITY

PCR N/A PCR

PCR PCR

10. CHANGE CLASS

CLASS I

CLASS II

11. REASON CODE

N/A



RETROFIT TCTO TO


T2 MOD


GII AIRCRAFT S/N 0080, MODIFICATION/INCORPORATION PER ATTACHED FLIGHT TEST BED DRAWING TREE GII50A0001 Rev S. GII AIRFRAME AND POWER MODIFICATIONS WERE PERFORMED BY SUPPLER. DELVERED MASTER DRAWING LIST NG-0100, BROUGT INTO ACCOUNTABILITY WITHIN CM PLAN CREW CHIEF FERRY FLIGHT SEAT INSTALLED PER GULFSTREAM REQT’S (RACK 4L) .*RELEASED FOR NEW ENGINEERING INCORPORATIONS PRIOR TO FLIGHT 055*

16. MFG. PLANNING

YES NO

17. DF NO

18.

EFFECT SCHED

19. MODEL CODE




N/A


ECP NUMBER 22. DEVIATION APPLICABLE

DEVIATION NUMBER

24. DOCUMENT/DWG NO

GII50F0001 25. DOCUMENT/DWG TITLE

NGC FLIGHT CONFIGURATION RELEASE 26. DOC/DWG REV

U 27. PL REV

N/A 28. NEXT ASSY PART NO (FOR REFERENCE ONLY)

G1159 29. NEXT ASSEMBLY FOLLOW-UP RA

YES ENTER SCHEDULED RA X NO

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REFERENCE FOLD DOCUMENT A7550P0005, REV C. A/C WEIGHT AND BALANCE REQUIRED PER GULF STREAM CMP, BEFORE FLIGHT AND AMENDED FOR SUBSEQUENT AIRCRAFT INSTALLATIONS. ATTACHED MATRIX INDICATES RA’S (DWG) RELEASED TO A/C ONLY ITEMS WITH SPECIFC PREP ITEMS HAVE BEEN INCORPORATED INTO A/C (N/A’S INDICATED CONFIGURATION TRACKING PURPOSES PER CM PLAN).


ORIGINATOR

M. FATTAL DATE

MATERIAL AND PROCESSES

DATE

/ / STRESS

DATE


DATE


DATE

/ / PROGRAM PLANNING

DATE


DATE

12/15/09 PROGRAM MANAGEMENT

DATE

/ / CHECK

DATE

/ / PRODUCT SUPPORT/ILS

DATE

/ / SAFETY

DATE

/

/

SOFTWARE CONFIGURATION MGMT

DATE

/ / CHIEF ENGINEER

DATE

/ / MANUFACTURING ENGINEERING

DATE

/ / RELIABILITY

DATE


DATE

/ / MASS PROPERTIES

DATE

/ / MEC

DATE

/ / MATERIEL

DATE


DATE


DATE


DATE / /

PRODUCT TEST

DATE

/ / DATA MANAGEMENT

DATE

/ / DADT

DATE

/ / PROGRAM MANAGER

DATE

/ / OTHER

DATE


M. FATTAL DATE

/ /


IRAD -1 ASSIGNED RELEASE AUTHORITY NUMBERS

LAST UPDATE: APRIL 20,

RELEASE AUTHORITY NUMBER DWG NUMBER DWG REV DRAWING TITLE

DATE RA ASSIGNED

DATE DWG RELEASED Flt/P.I. NUMBER

RA-IRAD-001 GII50A0001 B A/V INSTALLATIONS 20-APR-10 21-APR-10 027-002/004

RA-IRAD-002 XXXX I/R IRAD TRANSDUCER INSTALLATION XXX XXX 027-003

RA-IRAD-003 XXXX I/R FTB INSTALLATION DRAWING XXX XXX N/A

RA-IRAD-004 XXXX N FLIGHT TEST BED DRAWING TREE XXX XXX N/A

RA-IRAD-005 GII50F0001 K NGC FLIGHT CONFIGURATION RELEASE XXX XXX N/A

RA-IRAD-006 XXXX IR FTB INSTALLATION DRAWING XXX XXX N/A

RA-IRAD-007 XXXX B FAIRING MOD XXX XXX 035-018

RA-IRAD-008 XXXX A A/V INSTALLATIONS XXX XXX N/A

RA-IRAD-009 XXXX IR A/V INSTALLATIONS XXX XXX N/A

RA-IRAD-010 XXXX A FTB INSTALLATION DRAWING XXX XXX N/A

RA-IRAD-011 XXXX I/R DEMONSTRATION SYSTEM ATP XXX XXX N/A

RA-IRAD-012 XXXX I/R IRAD MASTER DRAWING LIST XXX XXX 040-024

RA-IRAD-013 XXXX I/R NGC IRAD to FTB INSTALLATION DRAWING XXX XXX 040-024

RA-IRAD-014 XXXX S FLIGHT TEST BED DRAWING TREE XXX XXX N/A

RA-IRAD-015 GII50F0001 R NGC FLIGHT CONFIGURATION RELEASE XXX XXX N/A

RA-IRAD-016 XXXX I/R DETAIL, RACK 5L C/B PANEL DETAIL XXX XXX 052-024

RA-IRAD-017 XXXX I/R XYZ ENGINE RUN GROUND ATP XXX XXX 052-025

RA-IRAD-018 GII50HWSWCM 14 HARDWARE SOFTWARE COMPATIBILITY MATRIX XXX XXX 052-026

RA-IRAD-019 XXXX B INTERCOM SYSTEM MODIFICATION XXX XXX 054-003

RA-IRAD-020 XXXX B FTA XYZ MASTER DRAWING LIST XXX XXX N/A

RA-IRAD-021 XXXX A UHF COM SYSTEM INSTALLATION XXX XXX 054-003

Engineering Release Tracking Matrix (Notational)


Flight Prep Sheet used to Track Configuration Changes on Vehicle

FLIGHT PREPARATION SHEET DATE

PREP ITEM NUMBER

JCN

MODEL NUMBER

SERIAL NUMBER

FLIGHT NUMBER.

CONFIGURATION CHANGE

HARDWARE

SOFTWARE

INSTRUMENTATION CHANGE

HARDWARE PLANNING ITEM W & B

SOFTWARE FRACAS ITEM OTHER REFERENCE DOCUMENTS

ZONE

RELATED FILES

PILOT SQUAWK DELAYED ACTION DCN/ADCN LTWO

INSP. SQUAWK OK FOR FLIGHT ITWO

INSP OK TASK DESCRIPTIONS

TEST SHOP INSP

AUTHORIZED BY

SPECIAL COMMENTS

ENTERED IN DATABASE (INITIAL)

OK TO FILE (STAMP)

DSF-1718 (6-01)*










Summary

• This CM Approach Has a Proven History of Success.– Several programs concurrently tracked on our GII.– Other programs have adopted this methodology


Questions

• Questions
