Attachment 0004 - Low Level Process Map.pptx

Low Level Process Map Basics Recommended Format Generic Example

Basics Low Level Process Map An evolution of a production flowchart, identifying Inputs – What’s needed at this step Outputs – What’s the product/result of this step Key Activities – What actions yield the step’s output Processing of inputs and previous steps’ outputs Safety Critical Characteristic (SCC) Notation All SCC-related information employs red color font or shapes Non-SCC information employs black color font

Recommended Format:

Critical Characteristics Process Map Contractor format is acceptable, provided the alternate format is explained (as in the following slides)

Critical Characteristics Process Map Format Level “n” Process Map Start Description Description Description 1.2 1.3 1.4 End Description Input Input Output Output Output Output Key Activities Key Activities 1.1 Key:

Input: -----

Output: -----

Process: -----

Critical Defect ----- “1.1” means this is a 2nd Level Map of Level 1’s Step 1 Red box means there is an SCC created or detected at a lower level Map Red Letters in Input, Output or Key Activities mean the SCC is created or detected at this very point in the Map Black lines denote Process Flow Key Activities Key Activities Key Activities Key Activities Key Activities [SCC] Key Activities Gov’t Notifications [Agency-Report] See next slide for Steps’ nomenclature Government notifications include the Agency(ies) and reports/documents used to communicate SCC

Step Nomenclature Description Inputs Outputs 1.2.1

Means Previous Next

Key Activities Safety Critical Activity [identify SCC] Identify SCC-related activity (creation or detection) in red font Spell out SCC within [brackets] Place blue/green boxes as to best fit within map

Example Representation of a Production Line for illustration and reference purposes

Safety Critical Characteristics (SCCs) Identified in this Map

Identify what SCCs are portrayed within the map Defects herein are used solely for illustration

State “No SCCs in map” for submittals without SCCs

Topmost Level Steps 1 & 4 identify the creation and detection points for the Safety Criticals (red text).

A lower level map may not be necessary Steps 2 & 3 identify Safety Criticals are either created or detected or both in a sub-processes.

A lower level map is necessary

Receive Materials & Parts Manufacture Components Assemble Components Package Assemblies Start End Suppliers’ parts Raw Material Parts Received Material Received Segregated non-conforming material Raw Material Standing Procedures Trained Personnel Receiving Inspection Inventory Operations Manufacturing Operations Accepted parts Segregated non-conforming material Suppliers’ Parts Standing Procedures Trained Personnel Specialized Equipment Manufacturing Operations Accepted assemblies Segregated non-conforming material Packaging Operation Shipping Inspection Standing Procedures Trained Personnel Specialized Pkg. Materials Assemblies Ready to Ship Segregated non-conforming material

Step 2 Detailed [1/2] Sub-Steps identify creation and detection of SCCs, as well as proactive measures to prevent them (e.g., in-process check) Sometimes the process inputs can be enable creation of SCCs Ovals are off-page connectors Disposition off-page connector refers to SCC non-conformance process handling Metal Treatment Material Inspection 2.4 Accepted parts Rough shape parts Inspection Process Test Standards Standing Procedures Qualified Personnel Heat Controls for [Material Structure Unsound] Forge Controls for [Material Structure Unsound] In-Process Mechanical Properties Test Non-Destructive Inspection for [Material Structure Unsound] Structurally checked parts 2.1 2.2 AcceptSCC?

Disposition No Manufacture Components Standing Procedures Equipment Set-ups Special Machining Operation for [Interface Threads Incorrect] In-Process Check for [Leak Rate Over Max] Machining Operations 2.3 AcceptSCC?

Disposition No Final shape parts Yes

Step 2 Detailed [2/2] Note not every input or activity is SCC-defect related Step numbering reflects lower level All 2.x are part of Topmost Level step 2

Assemble Parts Final Inspection 2.3 Accepted Suppliers’ parts Standing Process Complete parts Calibration Standing Procedures Qualified Personnel Gages Heat Controls Finish Controls Mechanical Properties Test Automated Gage for [Leak Rate Over Max] Automated Visual for [Presence of Interface Holes] Manual Inspections Visual Inspections Inspected parts 2.4 2.5 AcceptSCC?

Disposition No

Step 3 Detailed Note inspection can happen at latter stages of production

Final Metal Treatment Final Inspection 2.3 No additional input Complete parts Calibration Standing Procedures Qualified Personnel Gages Heat Controls Finish Controls In-Process Mechanical Properties Test Automated Gage for [Interface Thread Incorrect] Automated Visual for [Incorrect Assembly] Manual Inspections Visual Inspections Inspected parts 2.4 2.5 AcceptSCC?

Disposition No Yes Included for illustration Not required

SCC Disposition Include sub-map addressing how SCC dispositions are handled Based upon Critical Characteristic Control Plans (CCCP) and/or Critical Plans of Action (CPOA) Only applies to SCCs

Assess Causes Notify Government Continue Production Contract Requirements Quantity Defect(s) in question Operations involved Malfunction facts Corrective Actions Shutdown (if required) Root Cause Analysis or 6 Sigma Methods or other failure resolution tools Present facts Present Actions Request Go-Forward approval Gov’t addresses Go-Forward 4.1 4.2 Approval by Gov’t?

No Yes Disposition Contract Requirements Re-Start Authorized Production resumed Complete Corrective Actions (as applicable) Re-Start production 4.3