PROGRAMS

1
NAFPI Working Session Denver, Colorado John
Williams, Aerojet August 9-11, 2005
DESIGNING
FOE
PROGRAMS
Into
SUPPLIER
2

• Agenda
• Customer Expectations of FOE
• Your Companys Overall FOE Plan
• Projected Differences of Customer Company
  Expectations
• Your Companys Flow-Down to Suppliers
• Projected Differences of Your Company Supplier
  Expectations

3
FOE Requirements Flow from Many Directions
Sources
Aerospace Customer
Managing Auditing Agency
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
Subassembly Detail Shops
4
FOE Flow-down Requirements need Contractors
Standardization
Raytheon Missile Systems-Purchase Order
Attachment TQA-166 Foreign Object Damage (FOD)
Prevention---Quality Clause The seller shall
establish and maintain an effective Foreign
Object Damage (FOD) Prevention Program to reduce
FOD using MIL-STD-NAS412 as a guideline. The
Sellers program shall utilize effective FOD
prevention practices. The program shall be
proportional to the sensitivity of the design of
product(s) to FOD, as well as, to the FOD
generating potential of the manufacturing
methods. The written procedures or polices
developed by the Seller shall be subject to
review and audit by the Buyer and/or government
representative, and disapproval when the Sellers
procedures or policies do not accomplish their
objectives.
Raytheon Flow-down Clause (Part of the EKV
Program Quality Summary) Standard Aerojet
procedures. Specific FOD and Contamination
Control Issues are defined and implemented on
drawings and process planning.
5
FOE Flow-down Requirements need Contractors
Standardization (cont)
Lockheed Martin Flow Down S5 Quality Assurance
Clause (not invoked on any programs at Aerojet
except GMD)states a good overview of what a FOD
Program should include along with reporting
auditing requirements)
THAAD Program Clause Establish a Foreign Object
Elimination (FOE) program to ensure process
specifications and operations minimize the
creation of foreign object damage (FOD) and
establish control of FOD through the detection
and removal of foreign material, prior to product
operation, that could damage the product. The
program shall be designed to ensure that FOE
policies, work instructions, and procedures are
established and implemented. The program also
shall ensure that affected employees are trained
in FOE policies and procedures and that
product is manufactured in an environment free of
foreign objects.
Lockheed Martin Flow Down Clause (Part of the
THAAD Quality Program Manual) The subcontractor
shall establish and maintain a program that meets
the requirements of P515987, The THAAD Supplier
Foreign Object Elimination Program. The Foreign
Object Incident Reports required by this document
shall be submitted to LMSSC-SSM for information
as SDRL item PA-14, Within two working days of
the discovery of the incident.
Lockheed Martin Flow Down Clause (Part of the
ATLAS Manufacturing Plan) The Subcontractor shall
establish a FOD Prevention Plan using NAS 412 as
a guide
6
FOE Requirements Must be Implemented during
Hardware Proposal Development
Proposal Development
Preliminary Engineering Design
Supplier Requirements
Make or Buy
Audits Surveillance
Manufacturing Assembly Test
Metrics Evaluations
7
FOE Requirements Must be Implemented during
Hardware Proposal Development
Proposal Development
Preliminary Engineering Design
Supplier Requirements
Make or Buy
Audits Surveillance
Manufacturing Assembly Test
Metrics Evaluations
8
Inject FOE Requirements into Existing Design
Procedures

• Use established lines of communication where
  possible
• System Engineering, Project Engineering or
  Program Management
• AerojetAddress FOE at the Team Essential
  Disciplines (TED)
• Proposal Tool addresses requirements including
  illities
• Producibility is part of the Design for Mfg
  Assembly section.
• Normally includes concepts for standard parts,
  modular
• assembly, tolerances, access, minimize
  fasteners, etc.
• FOE Design Requirements added here include items
  such as
• Minimizing Lock wire
• Avoid entrapment areas
• Inspect ability after assembly
• Protection Devices
• Avoiding through holes
• FO Tooling concerns
• FO Packaging shipping additions
• Etc.

9
FOE Requirements Must be Implemented during
Hardware Proposal Development
Proposal Development
Preliminary Engineering Design
Supplier Requirements
Make or Buy
Audits Surveillance
Manufacturing Assembly Test
Metrics Evaluations
10
Aerojet In-house Make requires Up-front
Producibility Planning

• Manufacturing Engineer assigned to interface all
  DFMA FOD concerns During Hardware
  Development.
• Evaluate Manufacturing, Assembly, or Test (MAT)
  Process for FOD Risk Potential.
• New Aerojet Command Media requires a Process
  Failure Modes Effects
• Analysis (PFMEA) to be completed for every new
  process.
• Adding process area FOD Point of Contact (FPOC)
  to the Review Team List
• If process determined FOD Sensitive or Critical
  then set up a separate meeting with all
  personnel involved in the (MAT) Process.
• All MAT, Engineering, support personnel
  required to attend Annual
• FOE Training

11
AEROJET ManufacturingAssembly Workplace Practices
Titan Pump Shop--FCA

• Eliminate Hardware Damage and FOD Migration
  through 5S FOE Disciplines
• Implement 5S to Sustain Level
• Shadowbox Tools
• Clean-as-you-go
• Use Protective Covers immediately

Before 5S FOE
12
Manufacturing Process Reviews assure FOE
Requirements Addition
Manufacturing Process Review Teams
People
Review
Improve
Safety FOE Error Prevention Reduce Cost Reduce
Cycle Time Process Knowledge
Mechanics Inspection M.E. Q.E. Design Support
Drawing Specification Planning Tooling
Specifications
Drawings
Assembly Instructions
13
FOD Critical Area Members Established Goals
Strategy - Eliminate FOD Potential in FOD
Critical Areas, improve quality

• Members Own Their FCAs
• Request Facility Upgrades
• Establish FCA Boundaries Controls
• Recommend Process Improvements
• Request Tool Control Modernization
• Implement 5S Plans Sustain
• Request FOD Awareness Tools Training

14
FOE Requirements Must be Implemented during
Hardware Proposal Development
Proposal Development
Preliminary Engineering Design
Supplier Requirements
Make or Buy
Audits Surveillance
Manufacturing Assembly Test
Metrics Evaluations
15
Supplier Producibility FOE Requirements Known
Up-Front

• At Aerojet
• Select Train a Supplier FOE Coordinator
• Understand establish the Criteria for
  Candidate Suppliers
• Separate Candidates according to following
  requirements
• Does Program require FOE flow-down
• Supplier has history of FOD Type Incidents
• Include Packaging
• Assemblies cannot be Inspected Internally at
  Close-out
• The Assembly will be shipped directly into an
  Aerojet
• FOD Sensitive or Critical Area.
• Is the product Safety, Cost, or Schedule
  Critical at the
• next assembly
• New or un-certified Supplier

16
Communicate Requirements with Candidate Suppliers

• Candidate Supplier List (with NO FOD Program
  Experience)
• Conduct FOD Risk Evaluation at Supplier---include
• Material Rep., FOD Specialist, Processes
  Specialist
• Design or Mfg. Engineer.
• Invoke Aerojet Quality Acceptance Requirement
  (QAR) per contract
• Customize QAR according to FOD Risk Evaluation
  Criticality

Modified Aerojet Supplier Quality Assurance
Clause The supplier shall establish and maintain
an effective Foreign Object Elimination
(FOE)/ Foreign Object Damage/Debris (FOD) Program
to reduce/eliminate FOD using NAS-412 As a
guideline. The program shall be proportional to
the sensitivity of the design of the product(s)
to FOD as well as to the FOD generating potential
of the manufacturing methods. The supplier
will document and investigate, determine root
cause, and eliminate Repetitive non-conformances
related to FOD incidents. The written
procedures developed by the supplier shall be
subject to review and auditing by Aerojet and
disapproval when the suppliers procedures or
policies do not accomplish their objectives.
17
Implement Supplier FOE Plans Tailor Controls
accordingly

• Evaluate Suppliers Existing Capability
• Good 5S Controls and FOD Awareness
• Does supplier deliver to other Aerospace
  Corporations
• Level 1 2 Suppliers should develop common
  flow-down
• requirements to Level 3 subs where possible.
• Conduct 5S FOD Seminars for all geographically
  located suppliers
• Set up Training Plans to help bring Supplier on
  board ASAP
• Tailor FOE Plan according to Risk Criticality
• Interim Inspection, touch-labor training, FOD
  Area Controls,
• Shop planning controls, create a FOD Plan.
• Tailor Incident Reporting requirements for ease
  of submission.

18
Develop a Compliant FOE Program Across all
Supplier Levels

• Understand all customers requirements
• Existing Proposed
• Develop FOE Plan to the highest level requirement
  feasible
• Manpower Budget restrictions
• Communicate with Customers to evaluate use your
  
• company FOE plan instead of responding to vague
  flow-down clauses
• Auditing Incident Reporting
• Develop separate direct program costs for
  supplemental requirements
• Auditing, Reviews, Reporting Metrics
• Develop FOE Guidelines for suppliers during
  proposal planning
• FOD risk evaluation-- part of Supplier
  Qualification
• Develop / Open Communication Lines between
  Suppliers, Buyer, Procurement Quality, FOE
  Specialist, Design