Original Date: 09/14/1998
Revision Date: 01/18/2007

Based on performance specification MIL-PRF-38534, Raytheon Missile Systems Company (RMSC) developed the common process document, D-102, for the production of hybrid microelectronic assemblies (HMAs). This document enabled the company to standardize and improve its HMA production efforts by employing contractor self-governance, continuous process improvement, and team-based decision making.

Previously, the variations in specifications, standards, screening, tests, inspections, and procedures resulted in an array of processes which led to costly training and numerous errors. By standardizing the process, RMSC maximized product quality while minimizing the costs. Self-governance encouraged the entire RMSC team, including customers, to participate in the cooperative development of processes to produce more efficient HMA manufacturing. Emphasis was placed on reducing the following: manufacturing cycle times; testing and screening levels; and defects at the earliest stage of the manufacturing process. Process controls were made to pursue best-cost reduction decisions, while staying focused on cycle time reduction and quality improvement. The company measured a wide range of data to identify the value-added changes.

Since implementing this effort in June 1996, RMSC significantly reduced its cycle times by 50% (Figure 2-3). Process results are monitored electronically and are available to team personnel, management, and customers. Not only has the team clearly accepted ownership of their process, but cross-functional team improvement efforts continue to be implemented. Nearly $1 million in annual cost savings has already been identified by the company. Efforts are currently underway to migrate the process throughout all of RMSC.

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