PROGRAMS

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

2. Agenda: • Customer Expectations of FOE • Your Company’s Overall FOE Plan • Projected Differences of Customer & Company Expectations • Your Company’s Flow-Down to Suppliers • Projected Differences of Your Company & Supplier Expectations

3. Level 1 Supplier Level 1 Supplier Level 2 Supplier Level 2 Supplier Level 2 Supplier Level 3 Supplier Level 3 Supplier Level 3 Supplier Level 3 Supplier 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 Contractor’s 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 Seller’s 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 Seller’s 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 Contractor’s 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 • Aerojet—Address 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 (MA&T) 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 (MA&T) Process. • All MA&T, 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 Improve People Review 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 FCA’s • 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 supplier’s 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