NASA Update on:
NASA Audit Management
Team (NAMT),
JAPC Status &
Counterfeit Parts
Mitigation Actions
Buck Crenshaw, JAPC – Deputy Chairman
NAMT Facilitator
Tony Gutierrez - JAPC Manager
July 20, 2011
Company Confidential
Boston, MA
July 19-22, 2011
1
NAMT use of ICOP scheme
• If a Center is AS9100 certified by an accredited third party,
there is no need for a QAAR (or even a 1st party internal
audit for that matter) to verify compliance with every
single AS9100 requirement. All requirements are not
equally important, and it is a poor use of NASA QA
resources to be revalidating compliance with non-essential
QMS requirements that registrars are already looking at
versus validating compliance with important non-AS9100
Quality requirements. I would even go as far as to cite
100% duplication of registrar audits as a violation of NPD
8730.5 risk-base QA. Note that QAAR audits are already
looking at reduced scope AS9100 attributes.
• Having a NASA auditor present during 3rd party audits
makes great sense.
2
NAMT use of ICOP scheme
Background
•Several NASA requirements documents have been published
for the purpose of providing NASA Headquarters insight into
NASA Field Centers, NASA Major Primes, and NASA’s Sub-Tier
Suppliers. The process for oversight in the Sub-Tier Supplier
is additionally clarified in a Memorandum of Agreement
(MOA) that implements the NASA Joint Audit Planning
Committee. This MOA establishes an integrated schedule and
addresses team membership and methods of operation for
the conduct of the audits of these Sub-Tier Suppliers.
•The purpose of the NASA Audit Management Team is to
accomplish the same functions as the JAPC does for Sub-Tier
Suppliers for the NASA Field Centers and NASA Primes.
3
NAMT use of ICOP scheme
• NAMT is a Government Team to provide NASA Management
and NASA Field Centers insight into the compliance to
appropriate Safety and Mission Assurance (SMA)
Requirements at the NASA Field Centers and compliance to
contractually imposed SMA Requirements at NASA Primes.
4
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS
QUALITY MANAGEMENT SYSTEM
4.1
Control of outsourced processes
Configuration Management
5
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS
PRODUCT REALIZATION
7.
Identification and Inspection of Key Characteristics
Supplier Quality Management (Purchasing)
Process control
Documentation of processes
Control of key characteristics
In process verification points
Criteria for workmanship
Validation, Monitoring, and Measurement of Special Processes
Identification of Monitoring/Measurement Status
Traceability of Product to Records of Objective Quality Evidence
Preservation of Product / Work Environment
Electrostatic Discharge
Foreign Object Debris/Damage
Cleanliness
6
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS
MEASUREMENT, ANALYSIS AND IMPROVEMENT
8.
Internal Audit
Monitoring, Measurement, and Control of Key
Characteristics
Control of Nonconforming Product
Corrective Action
7
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Customer Focus/Satisfaction
(5.2 & 8.2.1)
Information to be monitored and used for the
evaluation of customer satisfaction shall include, but
is not limited to:
» product conformity
» on-time delivery performance
» customer complaints
» corrective action requests.
Organizations shall develop and implement plans for
customer satisfaction improvement that address
deficiencies identified by these evaluations, and
assess the effectiveness of the results. (8.2.1)
8
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
QMS General requirements
(4.1)
The organization’s QMS shall address customer
and applicable statutory and regulatory QMS
requirements
Customer Focus/Satisfaction
(5.2)
Top management shall ensure that product
conformity and on-time delivery performance are
measured and that appropriate action is taken if
planned results are not, or will not be, achieved.
9
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Project Management
(7.1.1)
Addition: New requirement for planning and managing
product realization in a structured and controlled way
to meet requirements at acceptable risk, within
resource and schedule constraints.
Implementation/Audit Considerations:
Does the organization have a process to manage
product realization planning to ensure quality and
schedule are not compromised?
– How are project plans used to manage the
successful completion of projects?
10
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Risk Management
(7.1.2)
Addition: New requirement to implement a risk
management process applicable to the product and
organization covering: responsibility, criteria,
mitigation and acceptance. Implementation/Audit
Considerations: Does the organization have a risk
management process that addresses all of the
applicable requirements?
–Is the definition of risk appropriately understood and applied in
that process?
–Are risks successfully managed in the organization?
11
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Configuration Management
(7.1.3)
Focuses configuration management on the
product and how it is sustained throughout
product realization
12
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Approval status for suppliers
(7.4.1)
Revision: Added and provided examples of
“approval status” (e.g. approved, conditional,
disapproved) and examples of “scope of
approval” (e.g. product type, process family).
13
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Approval status for suppliers
(7.4.1)
Revision: Added and provided examples of
“approval status” (e.g. approved, conditional,
disapproved) and examples of “scope of
approval” (e.g. product type, process family).
The organization must define the process for
suppliers approval status decisions or changes.
Recognition that the industry trend is to use
externally provided supplier performance data
(e.g. Online Aerospace Supplier Information
System –OASIS, Nadcap)
14
JAPC HIGH RISK QUALITY SYSTEM ELEMENTS FROM
AS9100C
Production Process Verification
(7.5.1.1)
Requirement to verify the production processes,
documentation and tooling are capable of
producing parts and assemblies that meet
requirements. This process shall be repeated
when changes occur that invalidate the original
results(e.g. engineering or manufacturing
processes changes, tooling changes).
15
Joint Audit Planning Committee (JAPC) status
• As a consequence of any CB exceeding triggers and being
asked for a corrective action plan to the RMC the JAPC will
conduct a supplemental oversight audit in conjunction with
any JAPC 2nd party audit scheduled during the following
year.
• Several JAPC audits currently in coordination phase.
• Significant activity as NASA transitions from the Shuttle and
Station assemble to commercial space services.
• Significant issues as it relates to our NASA developed Heavy
Lift launcher.
• AAQG Space Forum has invited all of the Commercial Space
companies issued contracts to our next AAQG Space Forum
meeting in Long Beach in September.
16
Joint Audit Planning Committee (JAPC) status
• A goal has been established to have most NASA auditors
complete the AATT course. To date AATT has been
conducted at GSFC, GRC and JSC. A course has been
scheduled for KSC including DCMA personnel in September.
• If funding is available we intend to make AATT available to
JAPC members.
• The JAPC and NMAT is considering using some of the
standardized forms in AS9101D.
• The intention of both the NAMT and JAPC is to input audit
data into OASIS.
17
Counterfeit Parts Issue
111TH Congress - 2D Session - S. 3729
• AN ACT to authorize the programs of the National
Aeronautics and Space Administration for fiscal years 2011
through 2013, and for other purposes
• S.3729 Congressional Authorization Bill for FY2011 through
2013 requires that counterfeit part identification training
be established for all employees that procure, process,
distribute, and install electronic parts that will:
– (A) teach employees how to identify counterfeit parts;
– (B) educate employees on procedures to follow if they suspect
a part is counterfeit;
– (C) regularly update employees on new threats, identification
techniques, and reporting requirements; and integrate industry
associations, manufacturers, suppliers, and other Federal
agencies, as appropriate…
18
111TH Congress - 2D Session - S. 3729 (cont.)
• REQUIREMENTS.—In carrying out the program, the
Administrator shall establish:
– counterfeit part identification training for all employees that
procure, process, distribute, and install electronic parts …
– an internal database to track all suspected and confirmed
counterfeit electronic parts …
– a mechanism to report all information on suspected and
confirmed counterfeit electronic parts to law enforcement
agencies, industry associations, and other databases, and to
issue bulletins to industry …
• REPORT TO CONGRESS.—Within one year after the date of
enactment of this Act, the Administrator shall report on the
progress of implementing this section to the appropriate
committees of Congress.
19
NPD 8730.2C, NASA Parts Policy
• ATTACHMENT B: Counterfeit Parts Control
Plan Contents
– Assess potential sources of supply to
determine the risk of receiving non-authentic
parts...
– Mitigate risks of procuring counterfeit parts
from sources other than OCMs or authorized
suppliers.
– Include applicable contract/purchase order
quality requirements related to counterfeit
parts prevention. Examples of quality
requirements are provided in AS5553,
including: …
– Specify contractor flow down of applicable
counterfeit parts prevention requirements to
their subcontractors.
20
NPD 8730.2C, NASA Parts Policy (Cont.)
• Product Assurance Process: Assess potential sources of supply
to determine the risk of receiving non-authentic parts... Also,
ensure Material control and disposition.
• Report nonconforming, defective, and/or suspected counterfeit for
all cases involving counterfeit parts or other potential fraud, to the
NASA Office of Inspector General and the NASA Director.
• Counterfeit Parts Training provided to-date:
FY11
NASA Center
CF Parts Control Plans
– October
GSFC
Drafted
– December
GRC
Released
– February
DFRC
Pre-Draft
– March
KSC
– April
SSC
– May
GSFC
– June
JSC
21
SAE G-19 Members
from Government, Defense and Industry Sectors
Aero Engine Controls
American Electronic Resource
Analytical Alternatives
Analytical Solutions
Applied DNA Sciences
Arcadia Components
Ares Corp
Arrow Electronics
Astute Electronics
BAE Systems (Operations)
BAE Systems
Ball Aerospace & Technologies
Boeing
Boeing Advanced Systems
Business Quality Process
Management
Bechtel Plant Machinery
CALCE University Of Maryland
Celestica Corp. Technology &
Engineering
China Aero-Polytechnology
Establishment
Creative Electron
Crestwood Technology Group
DA-Tech
Derf Electronics
Det Nortske Veritas (DNV)
DPA Components International
Celestica Corp. Technology &
Engineering
China Aero-Polytechnology
Establishment
Creative Electron
Crestwood Technology Group
DA-Tech
Derf Electronics
Det Nortske Veritas (DNV)
DPA Components International
Electronic Supply Chain
Solutions
Eltek Semiconductors
General Dynamics
General Dynamics UK
GE Aviation
Glenbrook Technologies
Goodrich Control Systems
Greenberg & Bass
Harris
Hi-Reliability Microelectronics
Hi-Rel Laboratories
Honeywell Aerospace
Electronic Systems
Honeywell Int'l
Honeywell Technology
Solutions
Infineon Technologies AG
Integra Technologies
Jabil Circuits
Jacobs Engineering
Jet Propulsion Laboratory
L-3 Communications - CSW
Left Coast Technical Solutions
Lockheed Martin Aeronautics
Lockheed Martin Missiles & Fire
Control
3M
Microram Electronics
Motronics Circuits International
Mouser Electronics
Nisene Technology Group
Northrop Grumman Electronic
Systems
N.F. Smith & Associates
NQA
Northrop Grumman
Orbital Sciences
Plexus
Premier Semiconductor Services
Process Sciences
Raytheon
Rochester Electronics
Sandia National Laboratories
Schlumberger HPS
Selex Galileo
Silicon Cert Laboratories
SMT Corp
SolTec Electronics
Sonix
Sonoscan
SRI International Sarnoff
Star Associates International
Trace Laboratories
TTI
22
G-19 Subcommittees
G-19 CI
Continuous Improvement Subcommittee
(AS5553A: Counterfeit Electronic Parts;
Avoidance, Detection, Mitigation, and
Disposition)
G-19 D
Distributor Subcommittee
(AS6081: Counterfeit Electronic Parts;
Avoidance Protocol, Distributors)
G-19
Committee
G-19 DR
Distributor Risk Characterization
Subcommittee
(ARP6178: Counterfeit Electronic Parts; Tool
for Risk Assessment of Distributors)
G-19 A
Test Laboratory Standards Development
Subcommittee
(AS6171: Test Methods Standard; Counterfeit
Electronic Parts)
G-19 C
Standards Compliance Verification
Subcommittee
23
Document Roadmap since AS5553
24
Questions?
25