QMS Status · GREEN · AS9100 Rev D + ISO 9001:2015 certified · last surveillance audit 2025-11 · zero major findings · CDRL A002 quarterly risk register submitted on time · 100% supplier qual records current · DCMA QAR resident.
NCRs · open
2
14 lifetime · 12 closed
CAPAs · active
3
all on track
Audits passed (12mo)
5 / 5
2 internal · 2 supplier · 1 customer
Supplier qual current
22 / 22
100%
Training expiring <30d
2
ESD recert + ITAR refresher
Tools cal expiring <60d
4
2 torque + 2 multimeters
📋 Recent QMS activity · last 14 days
| Date | Type | Item | Owner | Status |
|---|
| 2026-05-04 | NCR | NCR-2026-018 · EPS harness M3 fastener mis-torqued | M. Rodriguez | Closed · pass after rework |
| 2026-05-03 | Calibration | Torque wrench T-001 · annual cal due 2026-06-15 | K. Walsh | Scheduled |
| 2026-05-02 | Training | D. Chen · ESD recert expires 2026-05-30 | HR · K. Walsh | Recert scheduled |
| 2026-04-30 | Audit | Q1 internal audit · QMS-AUD-2026-Q1 · zero findings | K. Walsh | Closed |
| 2026-04-22 | NCR | NCR-2026-014 · COMM ferrite bead spec mismatch | M. Rodriguez | Closed · use-as-is |
| 2026-04-22 | CAPA | CAPA-2026-008 · ECO-2026-0142 ferrite bead spec | P. Reyes | Active · SAT-002 verification |
| 2026-04-15 | Supplier audit | Aerojet Rocketdyne · annual qual audit prep | P. Reyes | Scheduled 2026-06 |
🏆 AS9100 Rev D compliance
Certified through 2027-09
| Element | Status | Last review |
|---|
| Configuration Management | ✓ | 2026-Q1 |
| Risk-based thinking | ✓ | 2026-Q1 |
| FOD prevention plan | ✓ | 2025-Q4 |
| Counterfeit parts (AS5553) | ✓ | 2025-Q4 |
| Special-process control | ✓ | 2025-Q4 |
| Customer property | ✓ | 2026-Q1 |
| Subcontractor / outsource | ✓ | 2026-Q1 |
| Product safety | ✓ | 2026-Q1 |
📐 ISO 9001:2015 compliance
Certified through 2027-09
| Clause | Element | Status |
|---|
| 4 | Context of organisation | ✓ |
| 5 | Leadership | ✓ |
| 6 | Planning · risk + opp | ✓ |
| 7 | Support · resources / competence | ✓ |
| 8 | Operation · production / control | ✓ |
| 9 | Performance evaluation | ✓ |
| 10 | Improvement · CAPA | ✓ |
🔁 Cross-system QMS flow · how QMS connects to PLM · MES · Procurement
| Source system | Event | Lands in QMS as | Drives |
|---|
| MES | NCR raised on shop floor (Op-level) | NCR record in QMS | Disposition · USE-AS-IS / rework / scrap · CAPA if pattern |
| QMS pattern detection | 3+ similar NCRs in 90 days | CAPA opened · root cause analysis | May trigger Arena ECO if design fix |
| Arena PLM | ECO released (e.g., ECO-2026-0142) | CAPA verification + AS9100 config record | Verification on next build · effectiveness check |
| NS Procurement | Supplier qual expiring | Audit schedule entry | Audit + QSR review · re-qual decision |
| QMS Training | Training expiring < 30 days | HR notification + scheduling | Recert before expiry · prevent ITAR / cleanroom access loss |
| QMS Calibration | Tool cal expiring | Cal lab schedule | Pull tool from service · cal · return |
| DCMA QAR | Resident finding (verbal/written) | QAR finding record | Response + corrective action · close-out for next surveillance |
Lifetime NCRs
14
since 2024-12 award
Avg time to close
3.1 d
target ≤ 5d
USE-AS-IS rate
29%
4 of 14 (typical for ETO)
Repeat NCRs (same root)
0
CAPA effectiveness ✓
⚠ Non-Conformance Reports · 14 lifetime · click row for full disposition
| NCR # | Date | Description | Item | Source | Disposition | CAPA | Status |
|---|
| NCR-2026-018 | 2026-05-03 | EPS harness · M3 fastener mis-torqued · re-torqued | EPS-HARNESS-PWR-MAIN | Stage 4 · Op 030 | PASS after rework | None | Closed |
| NCR-2026-014 | 2026-04-22 | COMM-RF-AMP ferrite bead spec mismatch | COMM-RF-AMP-XBAND | Stage 4 · Op 050 | USE-AS-IS for SN-001 | CAPA-2026-008 | Closed · use-as-is |
| NCR-2026-011 | 2026-04-08 | COMM-ASSY RF return loss marginal | COMM-ASSY-A | Stage 3 · subsystem FAT | PASS after retune | Note for SAT-002 | Closed |
| NCR-2026-006 | 2026-02-22 | Harness pin-out delta on connector J42 | EPS-HARNESS-PWR-MAIN | Stage 2 · sub-assy | PASS · drawing red-line | ECO opened | Closed |
| NCR-2026-003 | 2026-01-15 | BGA void exceeded 25% on OBC-MAIN U17 | CDH-OBC-MAIN-A | Stage 2 · sub-assy | PASS after rework | None | Closed |
| NCR-2025-088 | 2025-12-04 | COMM-RF-AMP ferrite bead (pre-ECO) | COMM-RF-AMP-XBAND | Stage 1 · Receiving | USE-AS-IS | CAPA-2026-008 | Closed |
| NCR-2025-064 | 2025-09-14 | EM-001 vibration test margin low | ADCS-STAR-MOUNT | EM Qual | USE-NEW (Rev B mount) | ECO-2026-0138 | Closed |
| NCR-2025-051 | 2025-07-22 | Wire harness sleeve missing on EM-001 | (EM-001 · misc) | EM build | PASS after add | None | Closed |
| + 6 historical NCRs · earliest 2025-04 · all closed · click "View all" to expand |
📊 NCR pattern detection · what triggers a CAPA
| Pattern | Threshold | Action | Owner |
|---|
| Same component · same root cause · 90-day window | 3+ instances | Open CAPA · root cause analysis | K. Walsh (QA) |
| Same operator · same op · 90-day window | 3+ instances | Re-training trigger | HR + QA |
| Single high-impact NCR (cost > $50K) | 1 instance | Immediate CAPA + customer notification (DCMA) | QA + DCMA QAR |
| Vendor quality slip (multiple NCRs same vendor) | 2+ instances/year | Supplier audit triggered + qual review | P. Reyes + K. Walsh |
| Counterfeit / suspect part | 1 instance | Immediate quarantine + GIDEP report | QA + Procurement |
Active CAPAs
3
all on track
Closed lifetime
8
100% effective
Avg cycle time
42 d
root cause → effective verify
Effectiveness rate
100%
no CAPA failures
🛠 Active CAPAs · root cause analysis + corrective + preventive
| CAPA # | Description | Origin | Phase | Effectiveness verify | Owner | Status |
|---|
| CAPA-2026-008 | RF amp ferrite bead spec mismatch · ECO-2026-0142 corrective | NCR-2025-088 + NCR-2026-014 | Effectiveness verify | SAT-002 build · part received from new spec | P. Reyes + K. Walsh | Active · verify Q4-2026 |
| CAPA-2026-005 | Star tracker mount margin · ECO-2026-0138 (Rev B mount) | NCR-2025-064 (EM-001 vib test) | Closed | SAT-001 SN-001 · margin 2.4 (was 1.15) | E. Garcia | Closed · effective |
| CAPA-2026-002 | BGA void rate above 15% on OBC suppliers | NCR-2026-003 + 2 historical | Action complete | 2 builds clean · monitor through SAT-002 | P. Reyes (vendor) | Monitor |
📋 CAPA-2026-008 detail · 8D problem-solving framework
| Step | Action | Owner | Status |
|---|
| D1 Team | K. Walsh (QA) · P. Reyes (Procurement) · E. Garcia (Eng) · DCMA QAR (notify) | K. Walsh | Done |
| D2 Problem | COMM-RF-AMP ferrite bead spec mismatched on 2 received units (NCR-2025-088 + NCR-2026-014) | K. Walsh | Done |
| D3 Containment | USE-AS-IS for SAT-001 SN-001 · all subsequent units verified vs new spec | K. Walsh | Done |
| D4 Root cause | Vendor (Tesat) replaced ferrite bead supplier without notification · spec dropped from BOM ECN list. Combined: vendor + Turion BOM control gap. | P. Reyes + K. Walsh | Done |
| D5 Corrective | ECO-2026-0142 released · update spec + AML · vendor agreement updated to require sub-supplier change notification | E. Garcia + P. Reyes | Done · 2026-03-18 |
| D6 Implementation | SAT-002+ uses new spec · vendor agreement effective · Turion BOM control: AML monitor expanded to sub-suppliers | E. Garcia + P. Reyes | Done |
| D7 Effectiveness | SAT-002 first ferrite bead receipt verified · monitor for 2 builds · close after SAT-003 receipt clean | K. Walsh | Active · Q4-2026 verify |
| D8 Lessons learned | Capture in QMS lessons-learned database · share with industry peers via AS9100 forum (anonymised) | K. Walsh | Pending close |
Internal audits 12-mo
4
quarterly · all passed
Supplier audits 12-mo
8
all passed · 2 with minor
Customer audits 12-mo
2
USSF + DCMA
Surveillance audit (AS9100)
2025-11
zero findings · cert through 2027-09
Open findings
0
all closed-out
📋 Audit log · last 8 audits
Zero major findings · 2 minor (closed)
| Audit # | Type | Auditor | Date | Scope | Findings | Status |
|---|
| QMS-AUD-2026-Q1 | Internal | K. Walsh | 2026-04-30 | NCR / CAPA process | 0 | Closed |
| QMS-AUD-2026-002 | Supplier | P. Reyes + K. Walsh | 2026-03-18 | Blue Canyon Tech (annual) | 1 minor (lubricant trace) · closed | Closed |
| QMS-AUD-2026-001 | Customer (DCMA) | J. Ortiz (DCMA QAR) | 2026-02-12 | SAT-001 build · all stages | 0 | Closed |
| QMS-AUD-2025-Q4 | Internal | K. Walsh | 2025-12-31 | Calibration + training | 0 | Closed |
| SURV-2025-AS9100 | 3rd-party (BSI) | BSI auditor | 2025-11-04 | AS9100 Rev D + ISO 9001 surveillance | 0 major · 1 obs (training tracking) · closed | Cert through 2027-09 |
| QMS-AUD-2025-006 | Supplier | P. Reyes | 2025-10-22 | EaglePicher (annual qual) | 0 | Closed |
| QMS-AUD-2025-005 | Customer (USSF) | USSF program office | 2025-09-04 | SAT-001 CDR readiness | 2 minor (CDRL response time · doc rev tracking) · closed | Closed |
| QMS-AUD-2025-Q3 | Internal | K. Walsh | 2025-09-30 | Document control | 0 | Closed |
📅 Upcoming audits · scheduled
| Date | Type | Subject | Auditor | Prep status |
|---|
| 2026-06-15 | Supplier (annual) | Aerojet Rocketdyne | P. Reyes + K. Walsh (on-site) | Prep · ECP-0091 reviewed |
| 2026-07-31 | Internal Q2 | Calibration + training | K. Walsh | Scheduled |
| 2026-08-15 | Customer (DCMA) | SAT-001 functional test phase | J. Ortiz (DCMA) | Scheduled |
| 2026-09-04 | Supplier (annual) | L3Harris (high-priority post-expedite) | P. Reyes + K. Walsh | Scheduled |
| 2026-11-04 | 3rd-party surveillance | AS9100 + ISO 9001 surveillance | BSI | Annual cycle |
Active suppliers
22
all DPAS+ITAR qualified
Qual records current
22 / 22
100%
Qual expiring < 90d
2
EaglePicher · CAES
Avg OTD %
94%
12-mo trailing
Avg quality grade
A
17 A · 4 B · 1 C (Tesat watch)
🏭 Supplier scorecards · top 8 vendors · linked to NS Vendor master
| Vendor | Subsystem | Qual record | Last audit | Quality grade | OTD % | NCRs (12mo) | Next audit |
|---|
| Blue Canyon Tech | ADCS | QUAL-2024-008 | 2026-03-18 | A | 100% | 0 | 2027-03 |
| Sodern · ArianeGroup | ADCS | QUAL-2024-011 | 2025-09 | A | 96% | 0 | 2026-09 |
| EaglePicher | EPS · Battery | QUAL-2023-022 · expires 2026-08 | 2025-10-22 | A | 100% | 0 | Re-qual due 2026-08 |
| AAC Clyde Space | EPS | QUAL-2024-006 | 2025-08 | A | 92% | 0 | 2026-08 |
| CAES (Cobham) | CDH | QUAL-2023-018 · expires 2026-11 | 2025-11 | B | 88% | 1 (closed) | Re-qual due 2026-11 |
| Tesat-Spacecom | COMM | QUAL-2024-003 | 2025-06 | B · CAPA active | 92% | 2 (1 open) | Q3-2026 priority |
| Aerojet Rocketdyne | PROP | QUAL-2023-009 | 2024-08 | A | — | 0 | 2026-06 (expedite-related) |
| L3Harris | PAY | QUAL-2023-004 | 2024-04 | A | — | 0 | 2026-09 (high-priority) |
⚠ Vendor watch · risk-based oversight
| Vendor | Watch driver | Action | Owner |
|---|
| Tesat-Spacecom | Open NCR + CAPA-2026-008 · grade B | Q3-2026 priority audit · CAPA effectiveness verify | P. Reyes + K. Walsh |
| Aerojet Rocketdyne | Schedule slip (R-008) · expedite issued | 2026-06 audit · weekly status calls | P. Reyes |
| L3Harris | Critical-path payload · 32wk build · TPI on-site | 2026-09 audit · qual sub-test reviews | P. Reyes + E. Garcia |
| EaglePicher | Re-qual expiring 2026-08 | Schedule re-qual audit by 2026-07 | P. Reyes |
| CAES | Grade B · 1 closed NCR · re-qual 2026-11 | Re-qual audit · BGA void monitoring | P. Reyes + K. Walsh |
Active personnel
26
all certs current
ITAR-cleared
22
85% workforce
Expiring < 30d
2
D. Chen ESD · K. Walsh ITAR
Recert pass rate
100%
first-pass · 2-year window
👥 Personnel training matrix · key roles + certifications
| Personnel | Role | ITAR | ESD (J-STD-001) | Soldering J-STD-001 | Crimping | Cleanroom | Status |
|---|
| M. Rodriguez (EMP-1142) | Tech III · Build Lead | ✓ 2024-08 (3yr) | ✓ Current | ✓ Current | ✓ Current | ✓ Current | All current |
| D. Chen (EMP-0942) | Tech II · Receiving | ✓ 2024-05 (3yr) | ⚠ Expires 2026-05-30 | ✓ Current | ✓ Current | ✓ Current | ESD recert due |
| K. Walsh (EMP-0741) | QA-III · Quality Lead | ⚠ Expires 2026-05-15 | ✓ Current | — | — | ✓ Current | ITAR refresh |
| A. Patel (EMP-1018) | Tech III · Sub-assy | ✓ 2024-08 | ✓ Current | ✓ Current | ✓ Current | ✓ Current | All current |
| E. Garcia (EMP-0501) | AI&T Director | ✓ 2024-05 | — | — | — | ✓ Current | All current |
| P. Reyes (EMP-1042) | Procurement Lead | ✓ 2024-08 | — | — | — | ✓ Current | All current |
| T. Pierce (EMP-0001) | CTO | ✓ 2024-08 | — | — | — | ✓ Current | All current |
📋 Required training matrix · by role
| Role | Required certs | Renewal cycle |
|---|
| Mfg Tech III (cleanroom · ITAR-cleared) | ITAR · ESD · J-STD-001 (soldering) · Crimping · Cleanroom | 2-3 years per cert |
| QA Inspector | ITAR · AS9100 audit cert · ESD · Cleanroom | 2-3 years |
| Test Engineer | ITAR · ESD · Test-specific (vibration / TVAC / EMI ops) | 2 years |
| Procurement Lead | ITAR · DPAS · DFARS · Counterfeit parts (AS5553) · SAM.gov | Annual |
| Engineer (any) | ITAR · Cleanroom (visit-only OK without) | 3 years |
Calibrated tools
38
torque · multimeter · scale · etc
Expiring < 60d
4
2 torque + 2 multimeter
Cal lab
NIST traceable
A2LA accredited
🔧 Calibration log · top 10 most-used tools
| Tool ID | Type | Range / spec | Last cal | Next cal | Cal lab | Status |
|---|
| T-001 | Torque wrench (1/4") | 0.5-12 N·m · ±2% | 2025-06-15 | 2026-06-15 | Calibration Solutions LLC | Due in 42 days |
| T-002 | Torque wrench (3/8") | 5-50 N·m · ±2% | 2025-06-15 | 2026-06-15 | Calibration Solutions LLC | Due in 42 days |
| M-001 | Digital multimeter (Fluke) | 0-1000V · 0.01% accy | 2025-04-30 | 2026-04-30 | Fluke Cal Lab | Cal'd 2026-04-30 |
| M-005 | Digital multimeter (Keysight) | 0-100V · 0.001% | 2025-07-04 | 2026-07-04 | Keysight Cal Lab | Current |
| S-001 | Mass scale (1g res) | 0-10 kg · 1g | 2026-01-15 | 2027-01-15 | NIST traceable cal lab | Current |
| S-002 | Mass scale (0.1g res) | 0-1 kg · 0.1g | 2026-01-15 | 2027-01-15 | Same | Current |
| RF-001 | VNA (Vector Net Analyzer) | 10MHz-26GHz | 2026-02-22 | 2027-02-22 | Keysight | Current |
| O-001 | Oscilloscope (6 GHz) | — | 2025-09-04 | 2026-09-04 | Keysight | Current |
| L-001 | Laser alignment (collimator) | — | 2025-12-08 | 2026-12-08 | Newport Cal Lab | Current |
| P-001 | Pressure gauge (PROP test) | 0-3000 psi · ±0.5% | 2025-11-04 | 2026-11-04 | Pressure Cal Specialists | Current |
QMS procedures
62
document-controlled · revision tracked
Up-to-date
62 / 62
all rev current
Avg review cycle
2 yr
automatic review trigger
Reviews due < 6mo
8
routine cycle
📋 QMS procedures · top 12 (out of 62) · ISO 9001 / AS9100 anchored
| Doc # | Title | Type | Rev | Owner | Last review | Next review |
|---|
| QMS-001 | Quality Manual (top-level) | Manual | D | K. Walsh | 2025-09 | 2027-09 |
| QMS-002 | Document Control Procedure | Procedure | C | K. Walsh | 2025-09 | 2027-09 |
| QMS-010 | Configuration Management Plan (AS9100 4.3) | Plan | B | E. Garcia | 2025-12 | 2027-12 |
| QMS-015 | NCR Process | Procedure | C | K. Walsh | 2025-09 | 2027-09 |
| QMS-016 | CAPA Process (ISO 9001 Cl 10.2) | Procedure | B | K. Walsh | 2025-09 | 2027-09 |
| QMS-020 | Internal Audit Procedure (AS9100 9.2) | Procedure | B | K. Walsh | 2025-09 | 2027-09 |
| QMS-022 | Supplier Qualification + Audit | Procedure | C | P. Reyes + K. Walsh | 2025-09 | 2027-09 |
| QMS-030 | Counterfeit Parts Avoidance (AS5553) | Procedure | B | P. Reyes | 2025-12 | 2027-12 |
| QMS-035 | FOD Prevention Plan | Plan | B | M. Rodriguez | 2025-12 | 2027-12 |
| QMS-040 | Calibration Management Procedure | Procedure | B | K. Walsh | 2025-09 | 2027-09 |
| QMS-045 | Training + Competency Procedure | Procedure | B | HR + K. Walsh | 2025-09 | 2027-09 |
| QMS-050 | Customer Property + Property Records | Procedure | A | K. Walsh | 2025-09 | 2027-09 |
| + 50 more procedures · Special Process Control · Product Safety · Risk Mgmt · Supply Chain Visibility · etc. |
DCMA QAR resident
J. Ortiz
since 2025-04 · cleared
DCMA findings open
0
2 closed lifetime
DD-250 forms signed
2
PDR + CDR
CDRL response time
3.2 d avg
target ≤ 5d
🛡 DCMA QAR · resident inspector activity
| Date | Activity | Outcome | Doc |
|---|
| 2026-04-30 | Q1 surveillance review (CDRL A001) | Accepted · zero findings | DCMA-2026-Q1.pdf |
| 2026-04-22 | NCR-2026-014 disposition review | Concur · USE-AS-IS approved | DCMA-NCR-014.pdf |
| 2026-02-12 | SAT-001 build Stages 1-3 audit | Accepted · zero findings | DCMA-AUD-2026-001.pdf |
| 2025-09-29 | CDR signoff letter | Accepted · DD-250 signed | CDR-DD250.pdf |
| 2025-04-28 | PDR signoff letter | Accepted · DD-250 signed | PDR-DD250.pdf |
📋 Customer (USSF) interactions
| Date | Type | Activity | Outcome |
|---|
| 2026-04-22 | Quarterly review call | CLIN-003 status · A. McLamb · 60 min | Status accepted · no concerns |
| 2025-12-15 | Annual program review | USSF program office on-site | Status GREEN · positive |
| 2025-09-29 | CDR signoff letter | Customer + DCMA accepted | CDR baseline frozen |
| 2025-04-28 | PDR signoff letter | Customer + DCMA accepted | PDR baseline frozen |
| 2025-04-12 | PDR meeting · technical readiness | T. Pierce on-site · 4 hr | Strong technical confidence · ready for CDR |