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Ball Aerospace Program Process Tailoring Bringing Affordability across Space Mission Classifications Bob Manthy Director, Quality Management Systems February 2015

Ball Aerospace Program Process Tailoring - asq.orgasq.org/asd/2015/04/ball-aerospace-program-process-tailoring.pdfBall Aerospace Program Process Tailoring Bringing Affordability across

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Page 1: Ball Aerospace Program Process Tailoring - asq.orgasq.org/asd/2015/04/ball-aerospace-program-process-tailoring.pdfBall Aerospace Program Process Tailoring Bringing Affordability across

Ball Aerospace Program Process Tailoring

Bringing Affordability across Space Mission Classifications

Bob Manthy

Director, Quality Management Systems

February 2015

Page 2: Ball Aerospace Program Process Tailoring - asq.orgasq.org/asd/2015/04/ball-aerospace-program-process-tailoring.pdfBall Aerospace Program Process Tailoring Bringing Affordability across

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Space Mission Classification Framework Well Established

Industry framework provided by

─NASA NPR 8705.4, DoD Handbook 343

─Mission Risk Planning and Acquisition Tailoring Guidelines for National Security Space Vehicles 2010 (TOR-2011(8591)-21)

─Mission Assurance Guidelines for A-D Mission Risk Classes 2011 (TOR-2011(8591)-21)

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Spectrum of Program Risk Profiles Demands Process Agility

Multiple variable affect the ability to tailor in alignment with customer needs

─ Complexity of mission requirements

─ Command media and organizational maturity

─ Customer confidence in cost, performance, reliability, and risk capabilities

─ Demonstrated ability to adapt to a variety of customer requirements

National Needs

Programs

Operational

Systems

Development and

Demonstration

Research and

Development

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What is Process Tailoring?

Ball’s Program Process Tailoring system allows programs to meet the specific

expectations of multiple customers with differing needs

Ball Process

Program Specific

Execution Tailoring

Customer Needs

and Expectations

Program Execution

Aligned with Expectations

How

Cost

Schedule

Performance

Methodology

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Program Process Tailoring Foundation

Why Process Tailoring?

─Meet cost point by matching customer requirements for different types of missions

─Apply more cost effective path to same mission success endpoint

What does Process Tailoring mean?

─ Tailor execution strategy to save cost on low-likelihood risks

─ Same flight hardware processes with less evidence of assurance

─No change to mission risk or probability of success

─Greater tolerance for programmatic risk

How does Process Tailoring work?

─ Leverage mature processes and experience

─ Program flow down of requirements accommodates execution tailoring

─ Program specific control with documented tailoring

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Distinctions between Types of Risk

Mission Risk

─ Probability of inability to meet specifications on orbit

─ Example: Manufacturing defect leads to reduced mission life

Programmatic Risk

─ Probability of cost or schedule impact (as a result of reduced development rigor)

─ Example: Program does not screen electronic parts, so part defects would be found

later (costlier) in board or box-level functional or environmental testing

Acquisition Risk Tolerance

─Acceptance of risk by forgoing levels of oversight of the development process in

exchange from reduced development cost

─ Example: Customer not on parts selection board or approver of detailed designs

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Five Product Class Addresses Risk and Oversight

PC1 PC2 PC3 PC4 PC5

Critical operational

space systems

Human-rated space

systems

Commercial space

instruments, buses,

and components

Tactical Systems

Secondary space

instruments, buses,

and components

High-fidelity EDUs

EDUs

STE and GSE

Tooling

Prototypes

Models and mock-

ups

Shop aids

Comprehensive MA MA focused on

risk avoidance and

risk tolerance

MA limited to high

risk areas and

controlling the level

of uncertainty

MA limited to critical

interfaces

No MA

Comprehensive

requirements flow

down and design

analysis

Formal design and

review practices

Responsible

engineer designs

with peer oversight

and optional

formality

Specific engineering

analysis or

certification required

only in some areas

Basic design

requirements only

Comprehensive

customer oversight

at detail level

Significant

customer oversight

Limited customer

oversight

Modest or no

customer oversight

No oversight

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Why Product Class Methodology?

Agility - Execution Tailoring allows Ball to be cost competitive and

responsive to a breadth of customer mission requirements and

execution expectations

Strength - Product Class channels enable Execution Tailoring

1. Is the company internal language to set execution expectations

2. Defines dynamic range between process requirements

3. Provides pre-tailoring for efficient, program-specific tailoring

4. Selects material channel for procurements

TEMPO JPSS-1 WV-3

> > PC3 PC2 PC1

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Concept for Execution Tailoring

A

B

C

D

E

System

Elements

“C” Mission

Rqmts Met

Mission

Rqmts.

& Customer

Expectations

$$$

Product Segregation by • Difficulty of Requirements

• Heritage / experience

• Risk likelihood and impact

• End-item verification ability

• Evidence of assurance

• Required oversight

$$

$

Execution

Tailoring

(PC3)

(PC2)

(PC1)

Ball has a unique ability to meet all Mission Requirements at a lower cost

by tailoring Evidence of Assurance to focus where it matters

Voice of the Customer

Need an alternative to increasing mission risk

while reducing procurement cost

Process

Alignment “B” Mission

Rqmts Met

“A” Mission

Rqmts Met

Best

Value

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Mapping of Mission Class Maintains Acceptable Risk

Mission Risk Class Class A Class B Class C Class D

Ball Internal Product

Class or Product Type Class 1 Class 1: Operational

Class 2: Commercial Class 3

Class 3: Enhanced D

Class 4: Safety Only

Mission Success All Mission

Requirements Met

All Mission

Requirements Met

All Mission

Requirements Met

Driving Factors

• >> mission length

• Custom developed

• Highest Cost

• Customer oversight

• Low Pf: large

number of

mitigations

• > mission length

• Heritage developed

• Lower cost

• Customer

Insight/Oversight

• Low Pf: Part quality,

margins, redundancy

• < mission length

• Heritage developed

• Low cost

• Customer insight

• Corporate practices

• Low Pf: Part quality,

test actions

• << mission length

• Cubesat/Prototype

• Lowest cost

• Corporate practices

• Low Pf: Threshold

and safety focus

All Mission

Requirements Met

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Process Standards Ensure Quality Product Consistency

Internal Standard examples

─ Fastener processing

─ Packaging for contamination and

electrostatic discharge protection

─ Surface preparation for bonding

─Cleaning and preparation of aluminum

and aluminum alloy surfaces

─Material handling equipment

─ Foreign object debris (FOD) prevention

─ Parts de-rating

─ Fastener torque

External Standards

─AS9100C Certified Quality

Management System

─Others as required by contract

─Ball standard practices may exceed

external standard requirements

Process Tailoring does not permit deviation from applicable standards

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Execution Tailoring Methodology

1. Obtain clear understanding of customer expectations and values Mission needs

Programmatic needs

2. Tailor our product architectures and execution for cost control Timely information and transparency balance reduced evidence of assurance

Mission risk mitigation aligns to performance requirements

Programmatic risk mitigation aligns to contract requirements

─ Fixed price contracts allow Ball to control programmatic risk

3. Partner with customer for shared control Provide a high level of program insight

Provide customer timely information

Provide appropriate program influence and control

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Customers Follow Process Tailoring Capability

National Needs

Operational Systems

Demonstration

CRAD

IRAD

Orbital Express

STP3

NPP

Number of Major Hardware Programs

by Mission Type in 2014

MOIRE SBSS

WV3

Increasing Programmatic

Risk

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58 Years of On-orbit Mission Success

Page 15: Ball Aerospace Program Process Tailoring - asq.orgasq.org/asd/2015/04/ball-aerospace-program-process-tailoring.pdfBall Aerospace Program Process Tailoring Bringing Affordability across

Questions?

The Spectrum of Mission Risk Classes Demands Process Agility