A Strategic Approach for Foreign Object Elimination

1. A Strategic Approach for Foreign Object Elimination S. K. GuptaVice President, OperationsLockheed Martin Space Systems Company

2. Space Systems Products Fleet Ballistic Missile Atlas Launch Vehicles Mars Reconnaissance Orbiter One Strike and You’re Out!

3. You Are Working on Airborne Laser Are You the Only One Thinking About FOE?

4. Definitions • Strategic Approach • A plan, method, or series of maneuvers to reach a specific goal • Continuous Improvement • Doing something better today than it was done yesterday… • and doing something better tomorrow than it was done today

5. LMSSC Strategic Approach for Foreign Object Elimination GOAL: Foreign Object Elimination with 100% Mission Success STRATEGIC APPROACH: Engage All of Our Employees • in FOE Processes Throughoutthe Product Life Cycle • to Continuously Improve FOE Process Implementation

6. Challenge: Implement the FOE Strategic Approach Across 40 Different Programs with 75 Manufacturing, Test, And Integration Areas at Multiple Sites SWFPAC Valley Forge Sunnyvale Denver VAFB Huntsville Courtland San Diego SWFLANT Harlingen CCAS and ETR

7. Implement Foreign Object Elimination Across the Product Life Cycle

8. Implement FOE Across the Product Life Cycle Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture From Lust to Dust

9. Implement FOE Across Program Life Cycle Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture Not Just At Production!

10. Implement FOE Across the Product Life Cycle Operation Deployment Support Disposal Fabrication and Test Operations Product Assurance (Quality) Logistics Production Development & Acquisition Manufacturing and Test Engineering Design Engineering Business Development & Capture LMSSC FOE Process with Links to Other Disciplinary Processes Systems Engineering Program Management

11. Implement FOE Across the Product Life Cycle • Develop a Basic Program FOE Plan as Part of Initial Proposal to Identify Scope • Recognizes Cost / Benefit of a FOE Program • Customer Inclusion Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture FOE Programs Are Not Free

12. Implement FOE Across the Product Life Cycle • Update Program FOE Plan as System Design Firms • Develop System FOE Requirements for Design Requirement Flow Down (Both In-house and Suppliers) • Include at Preliminary and Critical Design Reviews Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture

13. Implement FOE Across the Product Life Cycle • Designate FOD Sensitive Products in Basic Engineering • FOE Requirements Flow Down to Manufacturing and Test Engineers For Inclusion in Work Instructions (Both In-house and Suppliers) • Designs Include FOE Considerations Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture

14. Implement FOE Across the Product Life Cycle • Designate FOD Sensitive Product Areas • Standardized yet Flexible With Tiered Requirements Levels (FOD Critical, Control, Awareness) Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture

15. Implement FOE Across the Product Life Cycle • Maintain FOE Process Discipline through Deployment, Support, and System Disposal Operation Deployment Support Disposal Production Development & Acquisition Business Development & Capture

16. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation

17. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation Create an Environment that…. • Recognizes people want to do quality work • Promotes involvement and creativity • Provides time and support resources to solve problems • Strives for continual improvement Dig for Problems Don’t Bury Them

18. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation Use cross functional teams to design and maintain robust FOE processes because….. • FOD is not Acceptable • We can no longer be person dependent

19. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation Process Analysis Tools Available: • 6S (Sort, Straighten, Shine Standardize, Sustain, Safety) • Mistake Proofing • Six Sigma • Cause and Effect Diagrams • Failure Mode and Effects Analysis (FMEA) • Pareto Analysis • Flowcharting • Design of Experiment (DOE)

20. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation Use 6S for FOD Sensitive Product Area Setups • Sort Segregate and discard • Straighten – Arrange and identify for use • Shine – clean daily • Standardize – Revisit the first 3 steps frequently • Sustain – Make 6S part of the culture. • Safety – Ensure the workplace is conducive to a injury free environment Increased Productivity

21. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation Mistake Proofing - Using Wisdom And Ingenuity To Create Devices That Prevent FO, Allowing Tasks To Be Done FOD Free Use Mistake Proofing for FO Incident Cause and Corrective Action Sustained FOD Free Processes Increased Productivity

22. Utilize Standard Process Analysis Tools to Continuously Improve FOE Implementation • Mistake Proofing Process Describe What Should Happen Develop Mistake Proof Device Describe Defect Or Problem Identify Gaps And Red Flags Perform RCA, Five Whys Try- Storm Apply Nasty Test Implement and Monitor Results Standardize Share Lessons Learned Describe What Did Happen Develop Mistake Proof Design Rapid Cycles of Management Review Sustained FOD Free Processes

23. Strategic Ideas for Continuous Improvement • Use Six Sigma Tools to AnalyzeSupport Discipline Processes • FOE Requirements Flow Down to Suppliers • Tooling Accountability from Area Tool Cribs • Control of Miscellaneous Small Parts as Part of Assembly Kitting • Out-of-Position Work Instructions for Inclusion of FOE Considerations • Facility Maintenance to Prevent FOE • Work Area Design to Prevent FOE Opportunity-rich environment!

24. LMSSC Strategic Approach for Foreign Object Elimination Airborne Laser Demonstration Flight July 2005 STRATEGIC APPROACH: Engage All of Our Employees • in FOE Processes Throughoutthe Product Life Cycle • to Continuously Improve FOE Process Implementation

25. FOE is not a cost, but an investment