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Report of Survey Conducted at Northrop Grumman Corporation, El REPORT OF SURVEY CONDUCTED AT NORTHROP GRUMMAN CORPORATION EL SEGUNDO, CA FEBRUARY 1998 Best Manufacturing Practices BEST MANUFACTURING PRACTICES CENTER OF EXCELLENCE College Park, Maryland www.bmpcoe.org F o r e w o r d This report was produced by the Best Manufacturing Practices (BMP) program, a unique industry and government cooperative technology transfer effort that improves the competitiveness of America's industrial base both here and abroad. Our main goal at BMP is to increase the quality, reliability, and maintainability of goods produced by American firms. The primary objective toward this goal is simple: to identify best practices, document them, and then encourage industry and government to share information about them. The BMP program set out in 1985 to help businesses by identifying, researching, and promoting exceptional manufacturing practices, methods, and procedures in design, test, production, facilities, logistics, and management – all areas which are highlighted in the Department of Defense's 4245.7-M, Transition from Development to Production manual. By fostering the sharing of information across industry lines, BMP has become a resource in helping companies identify their weak areas and examine how other companies have improved similar situations. This sharing of ideas allows companies to learn from others’ attempts and to avoid costly and time-consuming duplication. BMP identifies and documents best practices by conducting in-depth, voluntary surveys such as this one at the Northrop Grumman Corporation, El Segundo, California conducted during the week of February 23, 1998. Teams of BMP experts work hand-in-hand on-site with the company to examine existing practices, uncover best practices, and identify areas for even better practices. The final survey report, which details the findings, is distributed electronically and in hard copy to thousands of representatives from industry, government, and academia throughout the U.S. and Canada – so the knowledge can be shared. BMP also distributes this information through several interactive services which include CD-ROMs, BMPnet, and a World Wide Web Home Page located on the Internet at http://www.bmpcoe.org. The actual exchange of detailed data is between companies at their discretion. Northrop Grumman maintains core values of customer satisfaction, employee opportunity, environmental compliance, and community outreach. The overall philosophy is to draw upon skills throughout the company so that the very best technologies, processes, and intellectual capital are brought to each program. This outlook enables the company to achieve creative vision, environmental management, and financial advantage necessary to compete in the 21st Century. Among the best examples were Northrop Grumman’s accomplishments in elimination of ozone depleting chemicals; work in process cans; chemical tracking system; and Title V operating permits program. The Best Manufacturing Practices program is committed to strengthening the U.S. industrial base. Survey findings in reports such as this one on Northrop Grumman expand BMP’s contribution toward its goal of a stronger, more competitive, globally-minded, and environmentally-conscious American industrial program. I encourage your participation and use of this unique resource. Ernie Renner Director, Best Manufacturing Practices C o n t e n t s Northrop Grumman Corporation 1. Report Summary Background ......................................................................................................... 1 Best Practices...................................................................................................... 1 Information ......................................................................................................... 4 Point of Contact .................................................................................................. 4 2. Best Practices Production Cascade Closed Loop Cleaning System .............................................................. 5 Elimination of Ozone Depleting Chemicals........................................................ 5 Emission Factor Refinement ............................................................................... 6 Emissions Reductions .......................................................................................... 6 Environmental Control Room ............................................................................. 7 Environmental Training and Communications ................................................. 8 In-House Air Toxics Modeling ............................................................................. 9 Material Substitutions, Volatile Organic Compounds, and Air Toxics Reductions ............................................................................... 9 Plural Component Paint Dispensing for Touch-Ups........................................ 10 Pollution Prevention and Reductions ............................................................... 11 Smaller Sealant Tubes ...................................................................................... 13 Work-In-Process Cans ....................................................................................... 13 Management Chemical Tracking System................................................................................ 13 Environmental Inspection Program.................................................................. 14 Legislative and Regulatory Involvement .......................................................... 15 Leuzinger High School Environmental Academy Partnership ....................... 16 Title V Operating Permits Program.................................................................. 16 Water Quality Improvement Practices ............................................................. 17 i C o n t e n t s (Continued) Northrop Grumman Corporation 3. Information Facilities Electronic Natural Gas Metering System......................................................... 19 Management Chemical Review Board ..................................................................................... 19 APPENDIX A - Table of Acronyms ........................................................................ A-1 APPENDIX B - BMP Survey Team ......................................................................... B-1 APPENDIX C - Critical Path Templates and BMP Templates.......................... C-1 APPENDIX D - BMPnet and the Program Manager’s WorkStation ................. D-1 APPENDIX E - Best Manufacturing Practices Satellite Centers ..................... E-1 APPENDIX F - Navy Manufacturing Technology Centers of Excellence ......... F-1 APPENDIX G - Completed Surveys........................................................................ G-1 ii F i g u r e s Northrop Grumman Corporation Figures 2-1 Aqueous Degreaser Tank ........................................................................................... 5 2-2 Portable Air Pollution Control Equipment ............................................................... 7 2-3 Hazardous Waste Reduction ...................................................................................... 8 2-4 Air Toxics and VOC Reductions................................................................................. 9 2-5 Plural Component Mixing and Dispensing System ............................................... 10 2-6 Work-In-Process Can ............................................................................................... 13 2-7 Chemical Tracking System Architecture ................................................................ 14 2-8 Chemical Tracking System Interfaces .................................................................... 14 Table 2-1 Diverted Non-Hazardous Waste .............................................................................. 12 iii S e c t i o n 1 Report Summary Background a long, single production-specific line. Other key contracts include the Joint Strike Fighter, the The Northrop Grumman Corporation can trace J-STARS Aircraft Mod, and the B-2 Spirit Bomber its history back through the pioneering founders of programs. aviation — Jack Northrop, the Loughead [sic] broth- The southern California region is one of the most ers, Donald Douglas, and Leroy Grumman, to name regulated and environmentally restricted parts of a few. Over the years, the company transformed the United States for manufacturers. Northrop itself from an airplane manufacturer into a premier Grumman learned early on that the regulatory electronics and systems integration corporation. agencies did not have a good understanding of the Today, Northrop Grumman is a leading designer, aerospace industry, and thus the company has taken systems integrator, and manufacturer of military an active role in the environmental regulatory and surveillance and combat aircraft; defense electron- rule making process for many years. Only by compa- ics and systems; airspace management systems; nies working with regulators can rules be adopted information systems; marine systems; precision that will achieve their intended goals and work for weapons; space systems; and commercial and mili- both groups. Northrop Grumman also maintains tary aerostructures. core values of customer satisfaction, employee op- With its corporate headquarters in Los Angeles, portunity, environmental compliance, and commu- California, Northrop Grumman is organized into nity outreach. The overall philosophy is to draw five divisions, employs 52,000 personnel, and upon
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