taking the lead in land and maritime support xxi › mews › jp › 16th › pdf › presen ›...

XXIXXI

Defense Supply Center ColumbusTaking the Lead in Land and Maritime Support

Defense Logistics AgencyDefense Logistics Agency

QML PROGRAM MIL-PRF-38535

XXIXXI



TOPICS TO BE COVERED

• Defense Supply Center, Columbus• Operations Support & Testing Group and

Sourcing/Qualifications Unit (DSCC-VQ)

• DSCC-VQ mission and web pages

• Certification and qualification

• Rationale for QML

XXIXXI



TOPICS TO BE COVERED (cont.)

• QML-38535 Status Report

• Certification of Wafer Foundries

• Buying Die from an external source

• Commercial Off the Shelf and Upscreening

• Final remarks

XXIXXI



DEFENSE SUPPLY CENTER, COLUMBUS

• Supply arm of the Department of Defense• Inventory Control Point (ICP) of the Defense Logistics

Agency• One of three DLA Inventory Control Points for spare parts• Lead Center for Land and Maritime Support to the military

customers• DSCC is organized in Weapon Systems Teams to better

facilitate customer support• DSCC buys, manages, and coordinates shipments of

weapon systems and electronic parts for U.S. Military and NATO units around the world

XXIXXI


Defense Logistics AgencyDefense Logistics Agency Defense Supply Center, ColumbusDefense Supply Center, ColumbusTaking the Lead in Land and Maritime SupportTaking the Lead in Land and Maritime Support

DEFENSE LOGISTICS AGENCYDEFENSE LOGISTICS AGENCY

XXIXXI

Defense Supply Center Columbus, OH

Defense Supply Center Defense Supply Center Columbus, OHColumbus, OH

Defense Energy Support CenterFt Belvoir, VA

Defense Energy Support CenterDefense Energy Support CenterFt Belvoir, VAFt Belvoir, VA

Defense Supply Center Richmond,VA

Defense Supply Center Defense Supply Center Richmond,VARichmond,VA

LEAD CENTER: LAND, SEA

and MISSILES

LEAD CENTER: TROOP SUPPORT& GENERAL SUPPLY

LEAD CENTER: AVIATION

• $12.6 B Annual Sales• Support 1,390

Weapon Systems• $9.8 B Inventory• 20 M Annual Reqns

LEAD CENTER:ENERGY

Defense Supply Center Philadelphia, PA

Defense Supply Center Defense Supply Center Philadelphia, PAPhiladelphia, PA

XXIXXI



DLA Office of Counselfor the Columbus Region (DOCCR)

Commander_ _ _ _ _ _ _ _ _ _ _ _ _ _

Deputy Commander

Supply Chain Management Office (DL)

Internal Review Office (DI)

Readiness & BusinessOperations Office (O)

Customer AdvocacyGroup (N)

Procurement (P) OperationsSupport Group (V)Ron Bayless, Director

Office of Comptroller (R)

Product Testing Center (T)

Associate Director of Small Business (DU)

Directorate ofCorporateInformation (B)

Aerospace WeaponSystemsGroup (A)

Commodity-BasedApplication Group (C)

Maritime WeaponSystems Group (M)

Land-Based WeaponSystemsGroup (L)

Chief of Staff (DC)

Executive Support Office

(DE)

Public Affairs Officer (DEB)

Command Control Center ( CCC)

Equal Employment Opportunity Officer (DK)

Safety & Health Office (DW)

Military Personnel Officer (DM)

Joint Reserve Force Team (DM)

Office of Civilian Personnel (K)

Directorate of Emergency Services (I)

Office of Installation Services (W)

XXIXXI



OPERATION SUPPORT GROUP (V)

Lead OSG AssistantDelores Dickey

Document Control UnitControl Unit (VA)

Dave Moore

Value ManagementProgram Unit (VE)

Ernie Reid

Support Services (VC)John Copeland

Product VerificationUnit (VP)

John Elavsky

Sourcing andQualification Unit (VQ)

Robert Evans

StandardizationUnit (VS)

Samuel Merritt

TechnicalManagement Unit (VT)

Daniel Nettler

Deputy DirectorDarrell Hill

Director (V)Ron Bayless

XXIXXI



• Current DoD engineering missions– DoD Standardization Manager for electronic and construction parts

– Provide parts management support for DoD contractors

– Military Department PA/Agent for MIL Specs and Standards

– National qualifying activity for the U.S.

– ADMINISTER QUALIFICATION PROGRAMS (QPLs/QMLs/QSL) - DSCC currently controls 300 QPLs/QMLs with participation from over 1,000 manufacturers and labs.

DoD Standardization Missions at DSCC

XXIXXI



UNIQUE MISSION

• Electronic Standardization could be a separate DoD stand-alone activity

• Integrated into the ICP structure

• Document Standardization (DSCC-VA):– Home Page: www.dscc.dla.mil/offices/DOC_Control/– Mil Specs, Drawings (search), Std. Microcircuit cross-reference:

www.dscc.dla.mil/programs/milspec/

• Sourcing and Qualification (DSCC-VQ):– Home Page:

www.dscccols.com/offices/sourcing_and_qualification/ QPLs,QMLs, Labs: www.dscc.dla.mil/programs/QMLQPL/

XXIXXI



QML - Qualified Manufacturers List:

A list of processes and materials approved for use in building a wide array of products considered meeting DoD performance, quality, and reliability requirements. May also list individual products.

What is QML

XXIXXI



QML Certification Process

• Manufacturer contacts DSCC requesting to be in the QML program

• DSCC sends information packet to the manufacturer

• Manufacturer performs self assessment of their quality system against QML quality system then sends the results of the self assessment and their quality management plan to DSCC

• DSCC reviews manufacturer’s information. If acceptable, DSCC will set up a date for a pre-validation visit

XXIXXI



QML Certification Process (cont.)

• Pre-validation– Review/discuss manufacturer’s quality management plan

– Review/discuss manufacturer’s QML coverage• Facility, lines, technology, processes

– Set up validation date and schedule

– Review and select validation team members• Government, industry, customers

– Ensure manufacturer understands validation process and what is expected of the manufacturer and the validation team members

– Sample audit of areas to be covered during the validation

XXIXXI



QML Certification Process (cont.)

• Validation– Team members from government, industry, and specific customers audit

manufacturer’s facility, lines, and quality system

– Main QML concepts and components reviewed and verified

– Copy of validation concerns along with audit report given to manufacturer and team members

• Achieve QML certification

• Perform qualification testing and review the results

• List qualified parts on the appropriate QML

• Monitor manufacturer’s quality system via TRB quarterly report, self audit results, customer feedback, and a yearly management update

• Typically two year re-audit interval.

XXIXXI



Rationale for QML• No allowance for offshore manufacturing

• Significant improvements in industry quality and reliability

• Current state of the art products not being introduced on QPL

• Low volumes procured for military systems, many different device types

• Global competition

• Foresaw reduced manpower in out years

• Needed a specification flexible enough to recognize many different technologies and manufacturing lines and quality systems

XXIXXI



Rationale for QML (cont.)

• Needed one manufacturing process for both commercial and military

• Current military specification too restrictive

• Reduce/eliminate redundant audits from various customers/government agencies

• Eliminate non value added testing

• To align with the acquisition reform initiative by giving the OEM the authority to build and test products utilizing best manufacturing practices

XXIXXI



Commercial Off-The-ShelfElements to consider when performing risk analysis and determining total cost of ownership when using off-the-shelf commercial (data book) product in a military system

– Increased DMS Problems: Product life cycle of three to six years with approximately five to six revisions over the life

– DMS Situations Difficult to Manage: Lack of End of Life notices and no available after-market solutions

– Qualification Testing: Performed on each buy, for critical applications, due to the lack of major change notification

– Reliability Testing: Available data is directed towards high volume customer applications and environments. Military data does not cover COTS

– Methodology and Process for Supplier Selection: No technical support or data available for selecting known good suppliers

XXIXXI



Upscreening• UPSCREENING

– Warranty is voided

– User eats the cost of all failures (qualification and reliability testing)

– Screening survivors (quality is built in not tested in)

– Third party additional handling (reduced yield, reliability issues)

– Supplier approval

– Inventory

– Process change notice

Upscreening only provides confidence level testing. Quality can only be guaranteed by an assessment of the original manufacturer’s controls and processes. Upscreening should be performed as a last resort.

XXIXXI



Upscreening (cont.)

• Use of microcircuit devices outside the data book parameters guaranteed by the original manufacturer’s QML infrastructure (full characterization testing). However, when the QML product is not available refer to the references below for guidance in such methods as:

– Device parameter re-characterization

– Device stress balancing

– Device parameter conformance assessment• Naval Sea Systems Command (NAVSEA CRANE)

– Part Requirement and Application Manual

– http://pats.carne.navy.mil/component/applications.html

• Avionics Working Group (AWG) and International ElectrotechnicalCommission (IEC)

– Use of semiconductor devices outside manufacturers temperature ranges

– http://www.eccb.org/AWG/

XXIXXI



COTS/Upscreening Guidelines

• DSCC supports the procurement of commercial (off-the-shelf) data book product (COTS) where the COTS product (used as is) will meet the requirements of the military system and environment (e.g., system requirements, logistic support, performance, reliability and configuration control limitations)

However,However,

• Logistic support and configuration control must be carefully considered by contractors and SPOs for this level of product.

XXIXXI



COTS/Upscreening Guidelines (cont.)

IN ADDITIONIN ADDITION• Cost of ownership (life cycle costs) should be thoroughly evaluated to

assure overall cost effectiveness for DoD. To logistically support or to maintain configuration control on products that can be altered at any time without notice, by the original manufacturer and products which were selected based on lot to lot testing on each buy (e.g., screening, characterization, requalification) will be difficult and costly to sustain during the logistic phase.

• Hidden part costs (e.g., engineering evaluation, recharacterization, upscreening, qualification/reliability data collection, documentation) should be used in the cost of ownership models or comparisons of the various product grades.

XXIXXI



Purchase of Die from External Die Source

• Unable to perform a physical audit

• MIL-PRF-38535 required data concerning wafer processing not available from non-QML foundry

• No knowledge of major changes

• Purchased die post EOL, critical information missing/unattainable

XXIXXI



QML-38535 Wafer Fab / Foundry Certification

• SEM Process Monitor

• Major Change Notification

• Wafer process flows/travelers

• SPC

• Qualification and reliability testing for process technology(ies)

XXIXXI



Final Remarks

• The QML approach is basically a validation that the company is well managed and technically sound enough to be “world class” with minimum government interference

• QML manufacturers provide the military and space industry with guaranteed high reliability product

• Designing a QML device into a defense system is a smart decision because it demonstrates the contractor’s agreement that reliability is the responsibility of the user

• QML provides the user with the elements necessary to logistically support a system over its entire life cycle

taking the lead in land and maritime support xxi › mews › jp › 16th › pdf › presen ›...

Documents