SQAR Supplement for the F-35 Lightning II Program

Transcription

1 Aerospace Systems SQAR Supplement for the F-35 Lightning II Program : Approved (Signature on File) Tamara N. Lewis Director, Supplier Quality 1

2 REVISION RECORD The latest issue of this document may be confirmed by viewing the OASIS web site: at Revision Record New Updated Section 19 Packaging Requirements and 20 Tooling Requirements 13-JANUARY-2014 NOTE: Changes are identified by lines in left border. 2

3 Changes incorporated are: OVERVIEW This Supplier Quality Assurance Requirement (SQAR) Supplement details specific program requirements, which are in addition to the SQAR requirements unless otherwise noted. The requirements in the engineering specifications, purchase order and/or documents referenced in this supplement, shall take precedence over the requirements in SQAR. These program requirements are referenced to the applicable SQAR paragraph. As an example, a specific program requirement against SQAR paragraph 2.1 will be listed as paragraph 2.1 in SQAR Supplement. Additional requirements, not documented in SQAR are listed separately. INTRODUCTION This document provides direction to the supplier in support of the flowed down quality requirements and other program requirements for the F35 Lightning II Program. (Hereafter referred to F-35). The Quality Flow down requirements are contained within the Northrop Grumman Aerospace Systems (NGAS) Supplier Quality Assurance Requirements (SQAR) located on OASIS website: Supplier shall meet the quality criteria and standards set forth in Supplier Quality Assurance Requirements (SQAR) document in addition to those defined by this supplement. In the event that a conflict exists between the SQAR and this supplement, the supplement will take precedence. This document forms a part of Northrop Grumman purchase order, unless otherwise specified. SCOPE This document applies to all suppliers to the F-35 Program. The direction contained within this document applies to items procured by Northrop Grumman Aerospace Systems for the F-35 with both, NGAS Design Entity and Performance Base Specification type hardware. In addition, a list of F-35 Frequently Asked Questions (FAQ) is available on OASIS. 3

4 TABLE OF CONTENTS PARA Ref SQAR Para TITLE PAGE Overview 3 Introduction 3 Scope Nonconforming Material Control Product Release Records Shipping Documentation Requirements Key Characteristics Variation Management Foreign Object Debris/ Damage/ Detection (FOD) Supplier First Article Inspection (FAI) Part Marking Requirements Northrop Grumman First Article Inspection Review (EFAE) Manufacturing Plan Submittals For Critical And Designated Parts 9 SPECIFIC PROGRAM REQUIREMENTS 11 JSF DATA Library (JDL) 9 12 Engineering Materials & Approved Products 9 13 Product Data Management (PDM) System Approved Manufacturer List for Standard Parts (ASPECT) Measurement Plans Drawing Reviews Material Substitution Part Criticality Packaging Requirements Tooling Requirements 12 Definitions 13 Reference Documents 13 List Of Acronyms and Abbreviations 14 4

5 1 NONCONFORMING MATERIAL CONTROL/PREVENTIVE CORRECTIVE ACTION BOARD (PCAB) (ref: SQAR Para 2.2) Supplier shall provide status of Internal Corrective Actions associated with defects/ nonconformances, quality trends, major/top issues, etc. to be presented in Northrop Grumman, upon request. Ensure effective corrective and preventive action is taken (including repetitive non-conformances dispositioned Use-As-Is or Repair by Buyer s or Seller s Material Review Board [ MRB ] actions) to prevent, minimize, or eliminate non-conformances For product where Lockheed Martin Aero (LMA) owns the design Designed Items, Supplier s Material review process is limited to scrapping of items, eliminating the nonconformance by rework to engineering, or returning to vendor. Suppliers shall request repair or Use-as-Is disposition from LMA MRB upon written authorization from NGAS Buyer. Suppliers continued processing shall be limited to subsequent operations that do not hide, alter, or limit the ability to inspect, disposition or repair Item unless Seller has received written approval from Buyer. When Buyer has delegated MRB to Supplier for NGAS-designed Items, Supplier s process shall be limited to the scope provided in the MRB delegation. Supplier s request for Buyer MRB Disposition of Seller or Buyer-designed Items shall be submitted in accordance with Buyer instructions located at: For Supplier s with Design Authority, and a feature that affects Fit, Form, Function, Performance, etc., submit a Request for Variance in accordance with SDRL J0230. For NGAS Furnished Material that is scrapped during the manufacturing of an end item deliverable the supplier must inform NGAS. The notification can be accomplished by: Documented in accordance with SQAR 2.2 Nonconforming Material Control (through an MES-NC) Coordinated with buyer for notification purposes For deviations to Raw Material that is used prior to being fabricated, initiate a Request for Variance. NGAS Western Region MRB does NOT process known Raw Material anomalies. Under no circumstances shall the supplier deliver any non-conforming parts to NGAS without formal written authority. Additional information is detailed in NGAS Supplier Material Review Board Authority Guidelines SG

6 2 PRODUCT RELEASE (ref: SQAR Para 2.3) When Buyer s customer has delegated oversight/surveillance of Buyer s work to a cognizant Government representative at Seller s facility, Seller shall submit all material review dispositions for Buyer-related work to the cognizant Government representative, regardless of ownership of design and regardless of tier level for concurrence unless directed otherwise by your cognizant Government representative. 3 RECORDS (ref: SQAR Para 2.4) Buyer reserves the right to request the submittal of Records outlined in SQAR which shall be submitted within 48 hours. Supplier shall maintain and retain records in accordance with the SQAR. However, for Critical Parts the retention guidance document is 2ZZP00006 "Control of JSF Air Vehicle Critical Parts General Specification Document. Note: For Traceable Parts Record Retention see Traceability - 30 year requirement Applicable test reports shall accompany the final release documentation, if required by Engineering. Test reports can originate from tier 1 and lower tier suppliers. 4 SHIPPING DOCUMENTATION REQUIREMENTS (ref: SQAR Para 2.5) When traceability is invoked for Critical Parts, supplier shall complete the latest revision of form , Traceable Parts Data Input which can be accessed on OASIS. The form is required to accompany the product shipment. Certificate of Compliance (COC) shall be In accordance with 2ZZP00006, the COC shall include the Approved Manufacturing Plan revision letter or number, as applicable. For NGAS Source inspected items, Shipper and/or Certificate of Compliance shall have evidence of acceptance. Where component criticality is identified on the engineering this shall be clearly identified on the Certificate of Compliance (e.g., Fracture Critical Traceable ) 5 KEY CHARACTERISTICS (VARIATION MANAGEMENT) (ref: SQAR Para 2.10) The Supplier shall comply with the requirements of AS/EN 9103, Variation Management of Key Characteristics (KCs). Supplier shall manage the implementation, control, and monitoring accordingly. Supplier shall provide analysis Results and/or Records in Buyer s requested format monthly. In addition, the supplier shall provide inspection results in the Buyer s format/ portal monthly, unless otherwise authorized by Buyer. Contact your Buyer for applicable format and method of transmittal. 6

7 6 FOREIGN OBJECT DEBRIS/ DAMAGE/ DETECTION (FOD) (ref: SQAR Para 2.12) The supplier shall develop, implement and maintain a Foreign Object Debris/ Damage process that meets the requirements of NAS 412, Foreign Object Damage/ Foreign Object Debris (FOD Prevention). The FOD prevention program shall include the review of design and manufacturing processes to identify and eliminate foreign object entrapment areas and paths through which foreign objects can migrate. Supplier shall ensure work is accomplished in a manner preventing foreign objects or material in deliverable items. Supplier shall maintain work areas and control tools, parts and materials in a manner sufficient to preclude the risk of FOD incidents. Supplier shall document and investigate each FOD incident and ensure elimination of the root cause of each such incident. NGAS shall have the right to perform inspections, verification and FOD Prevention Program audits at Supplier s facility to ensure program documentation and effectiveness. Supplier shall identify a FOD control person responsible for implementing FOD prevention, awareness and training. Supplier s FOD prevention program shall include Supplier s periodic self assessment of its internal FOD prevention practices, including suppliers FOD Prevention Program at every tier, to measure effectiveness of program compliance to requirements. Supplier s FOD prevention program shall provide annual FOD training to Supplier s employees. At NGAS request, Supplier shall provide records of such self assessment and training to Buyer, upon request at no cost. Supplier s FOD prevention program shall, at a minimum, contain the following elements: Design & Manufacturing Process Review Performance Measurement Training Material Handling and Parts Protection Housekeeping, Tool Accountability Hardware Accountability Lost Items Physical Entry Control into FOD Critical Areas, and FOD Focal Point(s) Prior to closing inaccessible or obscured areas and compartments during assembly, Supplier shall inspect for foreign objects/materials. Supplier shall ensure that tooling, jigs, fixtures, and test or handling equipment are maintained in a state of cleanliness and repair sufficient to prevent FOD. By delivering Items to NGAS, Supplier shall be deemed to have certified to NGAS that such Items are free from any foreign materials that could result in FOD. 7

8 7 FIRST ARTICLE INSPECTION (FAI) (ref: SQAR Para 3.1) Supplier shall submit FAI Records upon request in Buyer s format and/or method within 48 Hours. F-35 Program major aircraft assemblies such as Center Fuselage sections are not subject to FAI, but traditional product verification tools and practices will be conducted to ensure conformance to the engineering and integrity of build processes (e.g. through a Product First Build review). 8 PART MARKING REQUIREMENTS (ref: SQAR Para 3.2) SQAR Part Marking Requirements is not applicable to the F-35 program Part marking shall be performed in accordance with: 2ZZP00008 Marking Specification for JSF Aircraft and Support Equipment CMA-0003G, Configuration Management Requirements for Suppliers and Subcontractors - Imposes prime contract CM requirements for SDD 2YZA00017, Configuration Management Requirements for F-35 Suppliers and Subcontractors - Imposes prime contract CM requirements for LRIP and follow on production contracts 2ZZP00008, Marking Specification for JSF Aircraft and Support Equipment (and applicable Variations) SERIALIZATION Composite parts serialization shall be in accordance with 2ZZP00004 Process Specification for the Manufacture and Quality Control of JSF Non-Specific Part Families Fabricated From LMA-MA002 and/or LMA-MB002 Material Serial numbers must be unique for the given part number. All suppliers are required to be registered with a CAGE Code. See the Defense Logistics Information Service Website at for details. Where required by the Engineering, the contracted Serial Number requirements are detailed in document Configuration Management Requirements for Suppliers and Sub-contractors (2YZA00017 or CMA-0003G as applicable). This document is included in the F-35 Program Flow down requirements within the respective purchase orders and business agreements. In summary, the document details that the serial number shall be a maximum of 10 digits long, and that the last 4 digits shall be numeric. Flight Science Critical part marking shall serialized be in accordance with 2ZZP00055, F-35 Flight Science Critical Parts, General Specification for Control of. Note: Flight Science Critical serial numbers shall not be reused for any new configuration of a basic part number produced by the same supplier Ref. paragraph 8

9 Serial number applies to the criticality serial number and the UID SEQ number. Neither should start from zero when a dash number is rolled. 9 ENGINEERING FIRST ARTICLE EVALUATION (EFAE) (ref: SQAR Para 3.4) An additional First Article Inspection (FAI) may be required in the applicable specification. When required, Supplier shall have objective evidence of completion or a waiver (Form E1-076/E1-076A). Contact NGC Buyer 72 hours prior to need for EFAE. 10 MANUFACTURING PLAN SUBMITTALS FOR CRITICAL AND DESIGNATED PARTS (ref: SQAR Para 3.5) F-35 Durability Critical parts are exempt unless required by the engineering 11 JSF DATA LIBRARY (JDL) SPECIFIC PROGRAM REQUIREMENTS To be an effective Team Member, you must have access to the data. Most of the resources and tools available for the JSF F-35 program are located in JDL (e.g., Material and Process (M&P) Specifications, Standard Part Drawings, Process Codes, etc). The tools and resources labeled with [JDL] require you to have a JDL account. Contact your Buyer for instructions to obtain access. M&P Listings with revisions are also available on OASIS. 12 ENGINEERING MATERIALS & APPROVED PRODUCTS 12.1 LMA-D0006 defines the use and contents of the LM Aero Engineering Materials and Approved Products (EMAP) database The qualified materials and/or products (including any associated requirements) that are listed in the EMAP database (reference Section 3) shall be used / controlled as specified, including all Additional and Internal Requirements Notes. The Supplier shall check the use of all Raw Materials in EMAP for applicability and sources. This includes Industry Material (e.g. AMS Fuel Tank Coatings) The EMAP database contains Engineering-controlled raw materials required for LM Aero/Northrop Grumman F-35 products. It is a portion of the Design Support Database (DSD) Materials database and contains productive and nonproductive sections The external LM Aero EMAP internet site as follows: Manufacturers: Subcontractors: Distributors: Information on this web site is the most current LM Aero Engineering requirement for raw material references on drawings and in process specifications. Northrop Grumman suppliers 9

10 shall use only the information in this database for the procurement and receipt of raw materials used in the production of Northrop Grumman-designed parts. 13 PRODUCT DATA MANAGEMENT (PDM) SYSTEM 13.1 PDM is a Product Data Management system with a graphical user interface (GUI). It is a commercial off-the-shelf (COTS) system developed by UGS and has been customized by the LMAero PDM Development Team 13.2 PDM manages Technical Product Data and provides capabilities including: Authoring and maintaining product definition (e.g. Latest Revision, Finish, Raw Material, M&P Processes, etc.) Part Information (e.g. Inseparable vs Separable Assembly, Criticality, etc.) Supporting Documents CATIA models and drawings Engineering Bill of Material (EBOM) 13.3 Suppliers shall use PDM as the source of engineering definition unless authorized by Purchase Order. Suppliers that do not have PDM access shall obtain definition formally and submit a RCI (e.g. Assembly status, Raw Material, Finishes, etc.). 14 APPROVED MANUFACTURER LIST FOR STANDARD PARTS ASPECT 14.1 The LMA document number 2GNA00001 contains a list of manufacturers that were approved as sources of supply at the time of publication for the standard part numbers listed and is located on the JDL. This document is a flat file to the Part Classification and Management (PCM) system (sometimes referred to as "Aspect") by the F-35 Component Engineering group The approved manufacturers for parts are listed in the body of this document. The approved manufacturers that are listed are approved only for the source or manufacturer part number listed. Source or manufacturer part numbers other than those listed are considered unapproved. The source or manufacturer part numbers are considered approved only when made by the manufacturer listed to the drawing revision specified. If the source or manufacturer part number is manufactured by a company other than the one that appears in this list, it is considered unapproved. Callout part numbers that do not appear in this list are not approved for use on the program and have no approved sources The supplier shall provide an engineering review, evaluation, and disposition of Government Industry Data Exchange Program (GIDEP) issues on standard parts contained in the Seller s equipment. (Ref 2.2 Nonconforming Control f) GIDEP Alerts) Note: Northrop Grumman ASPL is not applicable to standard hardware (nuts, bolts, washer, etc.) that is ordered to military, federal or industry specifications. NGC ASPL is not applicable to Customer designed standard hardware (nuts, bolts, washers, etc) listed in the F-35 Approved Manufacture list of Standard Parts. 15 MEASUREMENT PLANS Any Measurement Plans contained within the F-35 Build-to-Packages (BTPs) provided to Seller are incorporated within the BTP for Buyer internal use only and require no Seller action. 10

11 16 DRAWING REVIEWS Supplier shall comply with Part Number and Part Revision in PDM at Package level, at time of Contract (Request for Proposal/Quotation) for the deliverable Line Item level as documented on the Purchase Order, unless identified different in Purchase Order. It is recommended that the Supplier retain the Part Revision Level extracted from PDM (e.g. Package, CATIA Model, Drawing Notes) in a log as objective evidence. Note: PDM Sequence level is excluded from configuration requirements. 17 MATERIAL SUBSTITUTION F-35 Approved Materials Substitution 2ZZA PART CRITICALITY 18.1 Where applicable and when 2ZZP00006 is identified on the engineering, the criticality shall be marked on the component For Durability Critical, if specification 2ZZP00006 is NOT identified in the Engineering, then the part is treated as Normal controls from a supplier perspective The full criticality description must be applied to the part unless size restriction prevents this whereby the above abbreviations i.e., FCT can be applied Criticality designation must be stated on all associated release paperwork. 19 PACKAGING REQUIREMENTS 19.1 Product shall be packaged in accordance with F-35 Supplier Packaging Requirements, S0-0302M Packaging and transportability techniques for protection of product, supplies, and equipment against deterioration and damage during transportation, handling, and storage Specific goal to focus attention on the need for special packaging and part protection of items in accordance with contractual requirements. Control in packaging and transportability by the use of specifications and/or drawings to ensure that each end product is safely delivered to the customer Instruction for an effective Packaging and Transportability Program by use of protection standards to prevent contamination, corrosion, and physical damage of parts and materials for worldwide military shipments by all modes of transportation Packaging Engineering Material Handling Manual PHST Parts protection requirements for the following components: Fracture Critical Traceable (FCT), Fracture Critical Non-Traceable (FCNT), Maintenance Critical (MC), Durability Critical, Mission Abort Critical, Safety Critical and finally, Flight Science Critical (including Traceable and Non-Traceable) parts and assemblies 11

12 20 TOOLING REQUIREMENTS 20.1 Upon receipt of any LMA furnished tool, Supplier shall notify Northrop Grumman Quality Representative who then will contact the LMA F-35 Supplier Quality Engineer to schedule an appropriate time to witness the opening of the container and visually inspect the tool and contents for completeness and/or damage Sealed containers (Lead Wire Seal) indicate that the tool is a Control Tool and requires completing the accompanying documents inside the container Supplier shall complete LMA Form FWP-1209 Tooling Gage Storage Record accompanying Control Tools, Master Tools or Inspection Gages or Form (Gage Storage Record) for LMA furnished tools when opening or closing the container as applicable Supplier shall enter discrepancies, if any, in the remarks column. If supplier does not receive the applicable form with the tool, Supplier shall coordinate with their Northrop Grumman Quality Representative to initiate an LMA e-spar requesting the correct form. These forms are not available externally. Should one of these forms be missing from the container, Supplier shall immediately make request for replacement forms from their Northrop Grumman Quality Representative In addition to completing the required form, Supplier shall; Verify all details are placed accordingly in container Verify tool is clean and free of rust or damaged Verify all loose details are shored or secured accordingly Verify all metal surfaces are oiled / prepared for storage Packaging and closure of containers prior to shipment of any tool Supplier contracted to fabricate or rework Special Tooling shall contact Northrop Grumman Buyer to submit access request. In accordance with LMA TMS-015 Note: LMA PM-4053 contains complete design, manufacturing and preservation requirements 12

13 DEFINITIONS Deviations: Deviations may be identified as Deviations, Waivers, Concessions, Nonconformances, Production Permits, and Variations. REFERENCE DOCUMENTS Northrop Grumman Documents Supplier Quality Assurance Requirements (SQAR) SG-0100: Supplier Material Review Authority Board Guidelines SG-0101: Supplier Product Acceptance and Delivery Guide SQARSUP-0100: SQAR Supplement for the Control and Use of Digital Datasets Lockheed Martin Documents CMA-0003G, Configuration Management Requirements for Suppliers and Subcontractors - Imposes prime contract CM requirements for SDD LMA-D0006 Engineering Materials and Approved Products 2GNA00001 Approved Manufacturer List for Standard Parts 2YZA00017, Configuration Management Requirements for F-35 Suppliers and Subcontractors - Imposes prime contract CM requirements for LRIP and follow on production contracts. 2ZZA05001 Authorized Material Substitutions For Use On F-35 Aircraft 2ZZP00006, Control of JSF Air Vehicle Critical Parts General Specification Note: For Traceable Parts Record Retention see Traceability - 30 year requirement 2ZZP00008 "Marking Specification for JSF Aircraft and Support Equipment" (and applicable Variations) 2ZZP00055, F-35 Flight Science Critical Parts, General Specification For Control Of 2YZA00946, Flight Science Critical Part Definition and Handling TMS-MC-015, Supplier Tooling Manual (Tool Manufacturing Specification - Material Control - 015) 13

14 LIST OF ACRONYMS AND ABBREVIATIONS CAGE CofC CSI DC EMAP FCN FCT JSF LMA MAC MC MRB NDI PO SC SPC Commercial and Government Entity Certificate of Conformity/Certificate of Compliance Critical Safety Item Durability Critical Engineering Material and Approved Products List Fracture Critical Non-Traceable Fracture Critical Traceable Joint Strike Fighter Lockheed Martin Aeronautics Company Mission Abort Critical Maintenance Critical Material Review Board Non Destructive Inspection Purchase Order Safety Critical Statistical Process Control 14