Original Date: 05/01/2000
Revision Date: 01/18/2007

Previously, Northrop Grumman Defensive Systems Division (DSD) spent 10,560 hours per year training and re- certifying 191 personnel to fulfill the requirements of MIL-STD-2000. Re-certification typically ran three days to complete the 24 hours of training. Operators and inspectors were required to take different classes and obtain separate certifications. In April 1997, a block contract change for the ALQ-135 program provided the company with an opportunity to revise its training practices and transition to the J-STD-001 Workmanship Training.

Following this event, Northrop Grumman DSD developed a customized, internal workmanship standard, 499- 000008, based on J-STD-001 and IPC-A-610. An eight-hour re-certification class was also created to familiarize personnel with the new standard. Operators and inspectors take the same class which eliminates separate certifications. The class involves a 35-mm slide test to demonstrate acceptance criteria, a written test to demonstrate specification knowledge, and a sample circuit card assembly (CCA) build to demonstrate proficiency. Re- certification periods were extended from 12 to 18 months based on an industry survey. Standard practices and policies include SP 16-18.00 Formal Classroom Training, On-The-Job Training, and Training Records; EB12-04.10 Training and Certification; I.P.2.4.0.13 Product Operations Training Center Inspection & Soldering Certification Policy; I.P.2.4.0.51 Product Operations Training Center; and I.P.2.4.0.52 Electrostatic Discharge (ESD) Training Certification Program.

Northrop Grumman DSD also maintains a state-of-the-art Product Operations Training Center to train and certify its production personnel. Instructors are certified for J-STD-001 and IPC-A-610 training through the Electronics Manufacturing Production Facility. The training center contains ten workstations, each equipped with a Metcal soldering station and a microscope. Classroom instruction includes J-STD-001 and IPC-A-610 specification requirements review, hands-on soldering and inspection, and both written and visual tests using 35-mm slides of soldering/assembly defects. The company maintains a database with the employee’s name, number, training class completed, certification date, and test score. A sample of each employee’s training CCA or work is also kept on record. Personnel are re-certified at least every 18 months, or earlier if random Process/Product Assessment audits indicate a need for additional training.

Since implementing the J-STD-001 Workmanship Training, Northrop Grumman DSD decreased its training from 10,567 hours for 191 employees in 1997 to 2,599 hours for 178 employees in 1999. Other benefits include dual certification for operators and inspectors, a streamlined training program, and a more flexible workforce.

For more information see the Point of Contact for this survey.