IAQG STANDARDS IMPLEMENTATION
AT
ROCKWELL COLLINS
GOALS, BENEFITS AND LESSONS
LEARNED
Primus Ridgeway, Jr.
Vice-President, Enterprise Product Assurance
Rockwell - Collins Inc.
I

Rockwell Collins (NYSE:COL) - A Leader In Aviation/Aerospace Advanced Communication,
Navigation And Surveillance Electronics For Government And Commercial Applications. We
Provide Product To The World's Aircraft Manufacturers And More Than 400 Airline Customers,
As Well As The World's Military Forces. We Have Manufacturing Operations In The United
States, Europe, Australia And Mexico, And >60 Service Centers And Service Bases Worldwide.
—
2004- $3.1 Billion in Sales
—
~ 15,000 Employees
—
AS9100, ISO9001, ISO14000, FAA Certified
—
Headquarters: Cedar Rapids, Iowa
Products and Application
Weather Radar
F-18 Flight Deck
Flight Deck Avionics
eTES – Total
Entertainment System
Flexible Displays
JHMCS
Joint Helmet Mounted
Cueing System
Rockwell Collins Major Locations
Flight Dynamics
Airshow
ATS
GS(Iowa)
CAS
Intertrade
Fab/CPC
SCQA
SV&V
TES
AQS&T
RC-Cert. Center
RC-UK
RC-Deutschland
KE-San Jose
GS – Comm. Sol.
RC-France
Passenger
Systems
BRS - Melbourne
KEO – Carlsbad
KEP - Irvine
GS (Texas)
RC-Australia
RCI’s Quality Management System Evolution
OLD
Maintain Quality
Assurance Program That
Verifies That The Product
Meets The Spec Prior To
Ship
Manufacturing Oriented
TO
NEW
Establish A Cost Effective
Single Quality Management
System That Validates The
Effectiveness Of All
Business Processes
Affecting Quality of ALL
Collins Products (HW, SW,
Data, Service)
Enterprise Oriented
ADOPTION OF AERO SPACE STANDARDS IS KEY TO THE
TRANSFORMATION
The Business Decision
Rockwell Collins Implemented a Single Quality
Management System for the Corporation
—
Based on Full 3rd Party Certification to AS9100,
—
Leverage Key Companion Standards such as
AS9103 and AS9102
This approach established a single best practice for
quality management of key RCI business practices
and product acceptance criteria for factory build and
repair both in house and all RCI service centers and
bases worldwide
Rockwell Collins Single Quality Management System
Quality Management
System
Product Acceptance
Standards
RC-QMS-P-023
RC-QMS-P-022
RC-QMS-P-021
RC-QMS-P-000
QMS
AMR Platinum
Certifications
Compliance
Lockheed Star Select
Rockwell
Collins
Commercial
And
Military
Products
Applicability
Northrop Grumman Key Plan
Etc.
Process
Boeing
D6-82479
Airbus
ABD 100
Sikorsky
SU 2000
System
ISO 9001:2000
AS 9100:2001
QMS
Aircraft Certification
Supplier Evaluation Prog.
Product Integrity
Workmanship Standards
Repair Standards
Modification Standards
Common Quality Training
Rockwell Collins Standards
QMS Focus In The Product Life Cycle
Process
Stakeholder
Manufacturing
Process
Life Cycle Value
Stream
Management
Process
Pursuit &
Order
Capture
Design
&
Develop
-ment
Procurement
Supplier
Control
Build
OEM
Install
Quality Control
Programs Quality Management
Mission/Focus

Identify and remove barriers to flow

Develop methods to enable seamless
product transitions between factories

Drive focus on improved yield thru
critical factory process

Effective implementation and
management of QMS System

Drive root cause analysis and C/A
for customer returns
Field Quality
Engineering
Software Quality Eng
Engineering
Design Process
Service
&
Support
Design Quality Eng

Ensure contract, customer and
regulatory requirements

Develop method to enable seamless
product transitions (design-production)

Provide Process Navigation & Mentor
Support

Validate performance of purchased parts
through RCI product life cycle

Supplier approval certification and
corrective action

Product source inspection

Establish single quality process in all RCI
locations

Validate business process compliance
and initiate C/A of at risk business
processes

Support Integrated Product Integrity
Program
Supply Chain Quality Assurance
Supply Base
Mgmt Process
Enterprise
Business
Compliance
Process Rockwell
Collins, Inc.
Product Integrity
System Validation
& Verification
Advanced Quality
Systems & Technology
Continuous Improvement Focus in Design

The Continuous Improvement Focus Of RCI Single
QMS Is Identification And Reduction of Process
Variability In The Life Cycle Value Stream Of Our
Products. In The Design Phase This Means
Identification And Management Of Key Process
Characteristics

AS9103 Provides An Effective Guide For Application
Of Industry Best Practices

For RCI AS9103 provided an effective baseline to
attack CoNC in the design Process
Cost Of Non-Conformance (CoNC)
Process Inefficiency
Warranty
Service Bulletins
Customer Penalty
Finished Goods Modifications
Losses are Obvious!
Rejects (Internal Failures)
ECOs
Consignments
Non-Standard Modifications
Scrap
MRB
Waste is obvious
Test
Equipment
Wear
Loss of
Future
Customers
Excessive
Overtime
Pricing
Billing
Errors
Loss of
New Contracts
Premium
Shipping
Costs
Loss of
Company
Reputation
Expediting
Costs
Root
Cause
Analysis
Overdue
Receivables
Waste is Difficult to see, calculate, and
realize, yet very real!
WASTE!$$$$$ Below the Surface!
Unutilized
Space
Lack of
Follow-Up on
Current
Programs
Handling
Managing
Corrective
Actions
Development Costs
of Poor Quality
Product
Intangible CoNC!
Planning
Delays
Excessive Field
Service
Expenses
Excessive
System
Costs
Unused
Inventory
Re-Test
Re-Inspection
Processing
Paperwork
Unnecessary
meetings-Time
with Customers
CoNC The Ultimate
Business Case !!!!!
AS9103
What is the Benefit
Control of Key Characteristics = Variation Reduction = < CONC $$$
Continuous Improvement
LCL
UCL
Component
SubAssembly
Test
Bench
UCL
LSL
USL
Component
SubAssembly
Test
Bench
LCL
UCL
USL
Component
Prevention
Reduce CONC
SubAssembly
Test
Bench
Efficiency
Top
Level
Test
Bench
Top
Level
Reduce Waste
Customer Value
Test
Bench
Increase Profits
Aircraft
Aircraft
Aircraft
CONC $ $ $
Top
Level
LSL LCL
CONC $ $ $
Test
Bench
USL
CONC $ $ $
LSL
AS9103 Encourages Focus on Design and Prevention
Percent of Total Incurred Costs Assigned
Enterprise Product Assurance
Resource Allocation
100%
Preventive Actions
Corrective Actions
80%
60%
40%
20%
0%
POC
D&D
BLD
S&S
FY01
0%
9%
90%
2%
FY05 Fcst
2%
21%
68%
9%
Future State
5%
45%
35%
15%
Stop Design Induced Defects From Reaching
Production
CoNC Cost per Defect vs Development Phase
Cost
Defect Escape Rate
$4,000
ECO
CoNC Cost
$1,433
$57
Req'mt Def
$143
Design
$430
BOM Release
Qual Test
Production
Source for Defect Cost (Analysis thru Test): Cost Benefits of Software QA Whitepaper,
North Carolina State University, Nov 2000
Lessons Learned


IAQG Standards Are A Key Component To An Overall
Continuous Improvement Plan
Get Management Support – Define The Business Case
—

Reducing Cost of Non-Conformance is a good one!
Keep It Simple – Use An Understandable Continuous
Improvement Model

Show Return-On-Investment. Get Finance Dept To
Validate The Savings

Report Results: Improved Quality, Reduced Costs,
Improved Delivery, etc. Advertise Successes!
Other Important Points
For Successful Implementation

Remember To Address “Social” Issues Of Any Standards
Implementation

—
Is The Business “Focused” On Developing a Best Practice
—
Are There Unresolved Business Cultural Differences? (Mergers)
Ensure The Foundations Are In Place
—
Right People, Willingness-To-Change, Commitment, Goals
— Strong Communication and Training Plan