IAQG STANDARDS IMPLEMENTATION

AT

ROCKWELL COLLINS

GOALS, BENEFITS AND LESSONS LEARNED

IPrimus Ridgeway, Jr.Vice-President, Enterprise Product Assurance Rockwell - Collins Inc.

Rockwell Collins (NYSE:COL) - A Leader In Aviation/Aerospace Advanced Communication,

Navigation And Surveillance Electronics For Government And Commercial Applications. We

Provide Product To The World's Aircraft Manufacturers And More Than 400 Airline Customers,

As Well As The World's Military Forces. We Have Manufacturing Operations In The United

States, Europe, Australia And Mexico, And >60 Service Centers And Service Bases Worldwide.

— 2004- $3.1 Billion in Sales

— ~ 15,000 Employees

— AS9100, ISO9001, ISO14000, FAA Certified

— Headquarters: Cedar Rapids, Iowa

   

  

F-18 Flight Deck

Weather Radar

eTES – Total Entertainment System

Flexible Displays

Flight Deck Avionics

Products and Application

JHMCSJoint Helmet Mounted Cueing System

Rockwell Collins Major Locations

RC-France

RC-UK

RC-Australia

RC-Deutschland

BRS - Melbourne

GS (Texas)

Flight DynamicsAirshow

KE-San Jose

KEO – CarlsbadKEP - Irvine

ATSGS(Iowa)

CASIntertradeFab/CPC

SCQASV&VTES

AQS&TRC-Cert. Center

GS – Comm. Sol.

Passenger Systems

TO

OLD

Maintain Quality Assurance Program That Verifies That The Product Meets The Spec Prior To Ship

Manufacturing Oriented

NEWEstablish A Cost Effective Single Quality Management System That Validates The Effectiveness Of All Business Processes Affecting Quality of ALL Collins Products (HW, SW, Data, Service)

Enterprise Oriented

RCI’s Quality Management System Evolution

ADOPTION OF AERO SPACE STANDARDS IS KEY TO THE TRANSFORMATION

The Business Decision

Rockwell Collins Implemented a Single Quality Management System for the Corporation

— Based on Full 3rd Party Certification to AS9100,

— Leverage Key Companion Standards such as AS9103 and AS9102

This approach established a single best practice for quality management of key RCI business practices and product acceptance criteria for factory build and repair both in house and all RCI service centers and bases worldwide

AMR Platinum

Lockheed Star Select

Northrop Grumman Key Plan

Etc.

BoeingD6-82479

AirbusABD 100

SikorskySU 2000

ISO 9001:2000AS 9100:2001

Aircraft CertificationSupplier Evaluation Prog.

RockwellCollins

CommercialAnd

MilitaryProducts

Workmanship StandardsRepair StandardsModification StandardsCommon Quality Training

Product AcceptanceStandards

Quality ManagementSystem

Rockwell Collins Single Quality Management System

Certifications

Process

System

QMS Product Integrity Rockwell Collins Standards

Applicability

RC-QMS-P-023

RC-QMS-P-022

RC-QMS-P-021

RC-QMS-P-000

QMS

Compliance

QMS Focus In The Product Life Cycle Process

Stakeholder

Pursuit & Order

Capture

Design &

Develop-ment

Procure-ment

Supplier Control Build

OEM Install

Service &

Support Mission/Focus

Manufacturing Process

Identify and remove barriers to flow

Develop methods to enable seamless product transitions between factories

Drive focus on improved yield thru critical factory process

Life Cycle Value Stream Management Process

Effective implementation and management of QMS System

Drive root cause analysis and C/A

for customer returns

Ensure contract, customer and regulatory requirements

Engineering Design Process

Develop method to enable seamless product transitions (design-production)

Provide Process Navigation & Mentor Support

Supply Base Mgmt Process

Validate performance of purchased parts through RCI product life cycle

Supplier approval certification and corrective action

Product source inspection

Enterprise Business Compliance Process Rockwell Collins, Inc.

Establish single quality process in all RCI locations

Validate business process compliance and initiate C/A of at risk business processes

Support Integrated Product Integrity Program

Design Quality Eng

Quality Control

Field QualityEngineering

Supply Chain Quality Assurance

Programs Quality Management

Product Integrity

Software Quality Eng

System Validation & VerificationAdvanced Quality

Systems & Technology

Continuous Improvement Focus in Design

The Continuous Improvement Focus Of RCI Single QMS Is Identification And Reduction of Process Variability In The Life Cycle Value Stream Of Our Products. In The Design Phase This Means Identification And Management Of Key Process Characteristics

AS9103 Provides An Effective Guide For Application Of Industry Best Practices

For RCI AS9103 provided an effective baseline to attack CoNC in the design Process

CoNC The Ultimate Business Case !!!!!

Intangible CoNC!Waste is Difficult to see, calculate, and

realize, yet very real! WASTE!$$$$$ Below the Surface!

Warranty

Rejects (Internal Failures)

Non-Standard Modifications

ECOs

Finished Goods Modifications

Consignments

Customer Penalty

Scrap

Losses are Obvious!Service Bulletins

MRB

Process Inefficiency

Excessive Overtime

Loss of New Contracts

Planning DelaysPremium

ShippingCosts

Excessive FieldService

Expenses

Loss of Future

Customers

UnusedInventory

ProcessingPaperwork

UnutilizedSpace

ExpeditingCosts

Unnecessarymeetings-Time with Customers

PricingBillingErrors

Development Costsof Poor Quality

Product

HandlingManagingCorrective

Actions

RootCause

Analysis

ExcessiveSystemCosts

OverdueReceivables

Loss of Company

Reputation

Re-TestRe-Inspection

TestEquipment

Wear

Lack ofFollow-Up on

CurrentPrograms

Cost Of Non-Conformance (CoNC)

Waste is obvious

Component

Sub-Assembly

Top Level

Test Bench

Aircraft

Test Bench

USLLCL UCLLSL

CO

NC

$ $ $

AS9103 What is the Benefit

Control of Key Characteristics = Variation Reduction = < CONC $$$Control of Key Characteristics = Variation Reduction = < CONC $$$

USLLCL UCLLSL

Component

Sub-Assembly

Top Level

Test Bench

Aircraft

Test Bench

CO

NC

$ $

$

USLLCL UCL

Component

Sub-Assembly

Top Level

Test Bench

Aircraft

Test Bench

LSL

CO

NC

$ $ $

Prevention

Reduce CONC

Efficiency

Reduce Waste

Customer Value

Increase Profits

Continuous Improvement

Enterprise Product AssuranceResource Allocation

0%

20%

40%

60%

80%

100%

Per

cen

t o

f T

ota

l In

curr

ed C

ost

s A

ssig

ned

FY01 0% 9% 90% 2%

FY05 Fcst 2% 21% 68% 9%

Future State 5% 45% 35% 15%

POC D&D BLD S&S

Preventive Actions Corrective Actions

AS9103 Encourages Focus on Design and Prevention

Stop Design Induced Defects From Reaching Production

CoNC Cost per Defect vs Development Phase

$57 $143$430

$1,433

$4,000

Req'mt Def Design BOM Release Qual Test Production

Source for Defect Cost (Analysis thru Test): Cost Benefits of Software QA Whitepaper, North Carolina State University, Nov 2000

Cost Defect Escape Rate

ECO CoNC Cost

IAQG Standards Are A IAQG Standards Are A Key ComponentKey Component To An Overall To An Overall

Continuous Improvement PlanContinuous Improvement Plan

Get Management Support – Define The Business CaseGet Management Support – Define The Business Case

— Reducing Cost of Non-Conformance is a good one!Reducing Cost of Non-Conformance is a good one!

Keep It SimpleKeep It Simple – Use An Understandable Continuous

Improvement Model

Show Return-On-Investment. Get Return-On-Investment. Get Finance DeptFinance Dept To To

Validate The SavingsValidate The Savings

Report Results: Improved Quality, Reduced Costs,

Improved Delivery, etc. Advertise Successes!

Lessons Learned

Remember To Address “Social” Issues Of Any Standards

Implementation

— Is The Business “Focused” On Developing a Best Practice

— Are There Unresolved Business Cultural Differences? (Mergers)

Ensure The Foundations Are In PlaceEnsure The Foundations Are In Place

— Right People, Willingness-To-Change, Commitment, Goals

— Strong Communication and Training PlanStrong Communication and Training Plan

Other Important Points For Successful Implementation