Quality, Safety and Mission Assurance Directorate Overview

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Quality, Safety and Mission Assurance Directorate
Overview
Quality, Safety and Mission Assurance July 2008
Approved for Public Release 08-MDA-3636 (15 JULY
08)
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Why Quality, Safety and Mission Assurance?
Approved for Public Release 08-MDA-3636 (15 JULY
08)

• The frustrating part about it is we have not had
  an incident that, in my view, can be classified
  as a failure of the technology. . . Someone
  didnt perform a process right, somebody left out
  a piece of material where they shouldnt. . .
  Former MDA Director, Lt Gen Ronald Kadish,
  December 2003

The biggest challenge that were going to have
in the coming years is to work through the
problems that were going to have as a result of
quality control. We really do have a focus on how
we assure ourselves of quality control and
mission assurance in the various components and
elements. So weve moved from the question, Can
we do it? to Can we do it reliably? MDA
Director, Lt Gen Henry A. Trey Obering, Mar 16,
2005
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MDA/QS

• Mission Statement
• The Quality, Safety and Mission Assurance
  Directorate of the Missile Defense Agency
  performs a continuous assessment of the
  engineering, technology, processes, production
  and programmatic practices used to develop and
  operate the BMDS such that high risk attributes
  can be identified and addressed to increase
  confidence in achieving mission success while
  ensuring personnel safety.

Approved for Public Release 08-MDA-3636 (15 JULY
08)
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Background

• QS Directorate was created in late 2002, to
  address numerous mission failures
• QS Director,SES reports to the MDA Director
• Provides increased Government Involvement
  Process rigor
• Responsible for implementing and executing Agency
  Mission Assurance policy and procedures across
  all programs
• Responsible for the occupational health and
  safety of over 8000 employees worldwide

Approved for Public Release 08-MDA-3636 (15 JULY
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QS Organization
QS Leadership / Resource Management Board
QS Director
Deputy Director RSA
Deputy Director NCR
Chief Engineer NCR
BMDS
SOH/QS Ops
Audits/IRRT
ICQ
QSS - RSA Safety
QSA - RSA M. Assurance
QSQ - RSA Quality
QSI Field Support COS
Acq. Mgmt


Program Element
Airborne Laser ALQ
Aegis BMD ABQ
Ground-Based Interceptor GMQ
US-Israeli Coop Prog IPQ
THAAD THQ
KE Interceptors KIQ
C2BMC BCQ
Targets TCQ
Kill Vehicle KVQ
Sensors SNQ
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Reengineered QS Organization
Location of QSI Mission Assurance Representative
Various 75
QS COS 10 FTE
Lockheed, Denver, CO
ATK, Magna, UT
ALQ 5 FTE
Eagle Picher, Joplin, MO
Raytheon, Woburn, MA
Lockheed, Moorestown, NJ
Aerojet, Sacramento, CA
Lockheed, Sunnyvale, CA
ATK, Elkton, MD
Vandenberg AFB, Lompoc, CA
QS HQ 37 FTE
Boeing, Anaheim, CA
NGST/LAAFB, Huntington Beach, CA
Lockheed, Courtland, AL
Raytheon, Tucson, AZ
ABQ 17 FTE
Boeing, Huntsville, AL
Orbital, Chandler, AZPac Sci, Chandler, AZ
Raytheon, Camden, AR
PMRF,Kauai, HI
QS RSA 140 FTE
Ft. Greely, AK
Kodiak Facility, AK
Honeywell, Clearwater, FL
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QS Toolbox
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Mission Assurance And Safety Audits
MDA Assurance Provisions
MDA CEO Days
Pedigree Reviews
Lessons Learned
MDA Pedigree Review Certification
CEO
Supplier Roadmaps
Government / Industry Partnerships
Industry Stakeholder Initiatives
MDA
Mission Assurance Representatives
MDA Advisories
MDA Parts, Materials And Processes Plan
DCMA QA Letter of Delegation
QSMAUnfettered Access
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Unfettered Access Direction
Approved for Public Release 08-MDA-3636 (15 JULY
08)
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Mission Assurance Activities
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MDA Assurance Provisions (MAP)

• A standardized set of 14 QSMA provisions,
  requirements, and processes for mission and
  safety critical items
• Management
• Design and Development
• Software and Firmware
• Technical and Mission Assurance Reviews
• Reliability, Maintainability, and Availability
• Parts and Materials Control Program
• Integrated Test and Evaluation Program
• Test, Measuring and Diagnostic Equipment
• and Standards
• Interface Management
• Configuration Management
• Control of Nonconforming Items and Materials
• Fabrication and Quality
• Supplier Management
• Safety

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MDA Assurance Provisions (MAP) (Contd)

• Provide methods to measure, verify, and validate
  mission success through
• Collection and analysis of metrics
• Risk Assessment, technical evaluations,
  independent assessment, reviews
• Conducting tests
• Promote continuous process improvement to reduce
  cost, improve productivity, and assure SQMA
• Specific applicability is defined in Mission
  Assurance Implementation Plan (MAIP)
  Verification Matrix

MAP will be on all MDA contracts
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MDA Assurance Audits

• Based on 14 QSMA provisions outlined in the MAP
• Validate that end items at a selected level
  conform to engineering design requirements
• Validate end item at a selected level is
  qualified
• Compare fabrication methods and acceptance test
  levels against MDA industry standards as
  appropriate for MDA use
• Validate production readiness
• Assess Contractor/Government Mission Assurance
  practices, procedures, and implementation

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MDA Assurance Representatives

• MARs provide MDA with deployed Mission
  Assurance resources for direct and unfiltered
  supplier insight, with the leverage to effect
  value added change and mitigate risk in a timely
  fashion, and serve as MDAs Mission Assurance
  ambassadors to its Supplier community, associated
  agencies and organizations
• Responsibilities
• Rapidly identify, report and resolve technical
  issues on both hardware and software that impact
  the safety and reliability of the Missile Defense
  program
• Immediately report to the suppliers program
  office and to MDA/QS any safety concerns/issues
• Immediately report to MDA/QS significant
  hardware/software issues impacting upcoming
  missions
• Report and resolve safety, quality, and
  reliability issues/concerns impacting MDA
  hardware and software

Approved for Public Release 08-MDA-3636 (15 JULY
08)
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MDA Assurance Representatives (Contd)

• Responsibilities (contd)
• Represent QS Directorate and Cognizant Program
  Office
• Provides DCMA and contractor direct access to MDA
• Provides MDA Director unfiltered insight into
  program operations in real-time
• Participates in design integration, test,
  qualification activities and issue resolution
• Ensures that all applicable safety, quality and
  mission assurance provisions are being followed
• Disseminates lessons learned to counterparts at
  all BMDS components and DCMA
• On-site authority for QS LOD to DCMA

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MDA Assurance Advisories

• MDA Assurance Advisories (MAA) provide
  information about problems, potential problems
  and failure experience data on parts, components,
  materials, manufacturing processes,
  specifications, computer software, test equipment
  and safety
• Distributed as technical preventative action to
  all MDA programs so each program can make its own
  determination of applicability
• Originated out of the need to disseminate
  information rapidly across the Agency, faster
  than the existing GIDEP alert program
• Exchange of advisories improve quality,
  reliability, delivery schedules and reduce costs
• Implemented in October 2003, QS has published 34
  Advisories. Distribution to the MDA program
  elements, Industry, NASA, NRO and SMC

Approved for Public Release 08-MDA-3636 (15 JULY
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Parts, Materials And Processes Program

• State of MDA PMP Today
• Non-standardized PMP management
• COTS Technology and Obsolescence management lacks
  definition
• MDA lacks a comprehensive product engineering
  process
• MDA/QS PMP
• MDA-wide PMP Management Plan
• MDA Parts, Materials and Process Board/Control
  Boards
• MDA Preferred Parts List

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PMAP on Contract

• Parts, Materials, Processes Mission Assurance
  Plan
• Provides requirements and management structure to
  offset emerging part and material issues facing
  MDA
• OSD - Defense Standardization Program Office
  recognized PMAP as excellent high-reliance PMP
  plan for DoD

Approved for Public Release 08-MDA-3636 (15 JULY
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Supplier Roadmap

• Supplier Roadmap and Supply Chain Database
• 854 suppliers in 41 states and 6 foreign
  countries
• Can be searched by
• Congressional District
• State
• Supplier
• Program

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QS Safety Functions

• Our primary safety function is to independently
  verify that MDA products and operations are safe
  and assist elements in accomplishing this goal.
• Accomplished through participation in meetings,
  working groups, and milestone reviews detailed
  review of pertinent documentation to verify
  compliance with applicable standards oversight
  of selected operations and periodic audits.
• Principal MDA Safety Policies
• Directors Safety Policy (PM-12)
• Directors Decision on Safety, Quality, and
  Mission Assurance Realignment (1-Sep-04)
• MDA Assurance Provisions (MAP)
• Eastern and Western Range Safety Rqmts (EWR
  127-1)
• DN residual safety risk acceptance policy
  (1497-2004)
• Work Time Restrictions (PM-26)
• Mil Std 882

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BSO Mission
Approved for Public Release 08-MDA-3636 (15 JULY
08)

• The BMDS Safety Officer (BSO) is the on-alert
  BMDS technical authority responsible for the
  continuous monitoring of the BMDS, advising
  appropriate Combatant Commander Operations
  Centers on BMDS operation, performance, and
  availability while ensuring continuous safety.
  The BSO bridges the gap between technical and
  operational concerns, and is the forward deployed
  representative of the MDA Operations Center
  (MOC).
• Principal BSO responsibilities include
• Focus on BMDS safety and availability based on
  safety
• Advise appropriate Combatant Commander Operations
  Centers on the technical operation and readiness
  of the BMDS
• Ensure continuous safety, availability, and
  configuration control of the BMDS
• Monitor and report BMDS status, capability, and
  testing to include Periodic System Operability
  Tests (PSOTs) to the MOC and appropriate
  Combatant Commander Operations Centers

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MDA Directors Safety Policy

• Safety is our first priority and is an integral
  part of the process
• No compromise in accomplishing our mission safely
• Safety managers, supervisors, and executing
  agents are responsible for integrating safety
  program elements into MDA activities
• QS (Randolph Stone) is the MDA DASHO

Approved for Public Release 08-MDA-3636 (15 JULY
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Non-Advocate Safety Assessments

• Inadvertent firing of weapons
• Pre-launch hazards that could cause death or
  seriously injury to personnel
• Inclusion of BMDS sensors
• Specific focus areas
• Element interfaces
• Gaps in Element safety programs
• QS Non-Advocate safety Assessments are System
  safety assessments

Approved for Public Release 08-MDA-3636 (15 JULY
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Critical Ground/Flight Safety Considerations
Program/Range Safety

• Ordnance initiating systems
• Solid rocket motors segments
• Hazardous materials liquid propellants
• Pressure systems (pneumatic and hydraulic)
• Ionizing radiation
• Material handling equipment (cranes, slings,
  strongbacks)
• Computing systems software
• Work time restrictions
• Operations Safety

• Destruct system design
• Tracking and telemetry (TLM) system design
• Hazardous materials liquid propellants
• Destruct system redundancy/ single failure points
  
• Destruct decision criteria
• Impact Limit Lines/Flight Hazard Areas
• Launch/Impact Hazard Area Surveillance

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Approved for Public Release 08-MDA-3636 (15 JULY
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Safety Audits
Lead Safety Audits of Production Facilities for
compliance IAW DOD 4145M Common areas of
interest/findings FOD Issues Grounding Issues,
Housekeeping Issues Participate in SQMA audits
of MDA Programs Mitigation of hazards in
facilities/on sites
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Insensitive Munitions

• QS participates in the MDA Insensitive Munitions
  (IM) Board and develops the MDA Insensitive
  Munitions Strategic Plan
• MDA has developmental responsibility for its
  munitions
• Provide technical advice / recommendations
  concerning IM technology to program Milestone
  Decision Authorities, Program Managers, OSD,
  Joint Staff, and others.
• Review munitions acquisition programs in
  identifying IM science and technology
  opportunities.
• Provide advice / recommendations on integrated IM
  and Hazard Classification testing.

Approved for Public Release 08-MDA-3636 (15 JULY
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Safety and Occupational Health

• MDA SOH Directive
• Directive establishes Missile Defense Agency
  Safety and Occupational Health (SOH) program
  plans, policy, responsibilities, and guidelines
  for compliance with statutory, regulatory, and
  DoD policy/program directions. It also
  establishes MDA SOH programs designed for the
  protection of human resources through accident
  prevention, protection of MDA systems, property,
  and equipment and compliance with appropriate
  statutes, regulations, Executive Orders, and DoD
  policies.
• Involves the following
• Program Management SOH Training Requirements
• Education Publicity Risk Management
• Surveys and Inspections Hazard Controls
  Reporting
• Vehicle / Traffic Safety Process Safety
  Management
• Accident Investigations Reporting

Approved for Public Release 08-MDA-3636 (15 JULY
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Quality, Safety and Mission Assurance

• Increasing Quality Assurance rigor by
• Organizing for Mission Success
• Changing Culture
• Onsite MDA Mission Assurance Representatives
  (MARs)
• MDA Assurance Provisions (MAP)
• Defense Contract Management Agency (DCMA)
  Delegation of Authority Letter
• System and Range Safety Oversight
• Safety and Occupational Health

Approved for Public Release 08-MDA-3636 (15 JULY
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Mission Assurance Impact
Flight Test Successes
Approved for Public Release 08-MDA-3636 (15 JULY
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1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
Aegis
Notes
FM-5 6/03
FTR-1 7/00
-Arrow flight tests are not shown, program is
managed by the Israeli Government -Patriot flight
tests are not shown, program is managed by U.S.
Army
No Interceptor Failures
IFT-05 7/00
IFT-14 2/05
BV-3 12/01
BV-5 1/04
NMD/GMD
IFT-01 1/97
IFT-04 1/00
IFT-10 12/02
BV-2 8/01
IFT-13c 12/04
16 Flight Test / 0 Failures (0 failure rate)
THAAD
FT-08 5/98
FT-07 3/97
FT-09 3/99
22 Flight Test / 10 Failures (45 failure rate)
31 Flight Test / 4 Failures (13 failure rate)
QS Organization founded in Late 2002
In 2006 2007, there were no Interceptor test
failures