Weapon Quality Assurance (WQA) Process Model Use Guide, Version 1 March 2024

NNSA Weapon Quality Division (NA-121.3) Weapon Quality Assurance (WQA) Process Model Use Guide Version 1 March 2024 National Nuclear Security Administration (NNSA) Office of Defense Programs (NA-10) Office of Stockpile Management (NA-12) Office of Stockpile Production Integration (NA-121) WQA Process Model Use Guide ii March 2024 Revision History Version Number Description of Change(s) Release Date Version 1 Initial release version March 1, 2024 WQA Process Model Use Guide iii March 2024 Table of Contents 1 Tool Usage ................................................................................................ 1 2 Scope ....................................................................................................... 1 3 Navigating the Interactive Business Process Diagram ........................................... 2 4 Weapon Quality Assurance Process.................................................................. 5 4.1 F/PO Develops and Submits QAAP ................................................................................................ 5 4.2 NNSA WQD Plans and Conducts WQA Activities ....................................................................... 6 4.3 F/PO Executes to the F/PO QAAP .................................................................................................. 6 4.4 Use and Control of NNSA Accepted Product .............................................................................. 9 4.5 F/PO Analyzes WQA Performance Information and Documents Results .............................. 11 5 Key Definitions ......................................................................................... 12 5.1 WQA Processes Glossary Terms .................................................................................................... 12 6 Traceability References ............................................................................... 13 Appendix A: Weapons Quality Assurance Process Templates ................................... 14 WQA Process Model Use Guide iv March 2024 List of Acronyms Acronym Definition WQA Weapon Quality Assurance NNSA National Nuclear Security Administration WQD Weapon Quality Division F/PO Field/Production Office QAAP Quality Assurance Activity Plan FY Fiscal Year QAS Quality Assurance Survey WQMS Weapon Quality Management System PA Production Agency M&O Management and Operating Contractor QIL Quality Instruction List CAV Contractor Acceptance Verification COI Certificate of Inspection QAIP Quality Assurance Inspection Procedure IP Interproject UK United Kingdom DOD Department of Defense DA Design Agency NMR Nonconforming Material Report M&TE Measurement and Test Equipment WQA Process Model Use Guide 1 March 2024 1 Tool Usage This document is used in conjunction with R004, “Weapon Quality Assurance Processes.” R004 contains Federal requirements for implementing Weapon Quality Assurance (WQA) processes. 2 Scope This document provides instructions for using the interactive WQA Process Model (Figure 1). The WQA Process Model provides users with information, guidance, and documentation to help with implementing and completing the R004 WQA process federal requirements. NOTE Figures in this document have been hyperlinked to the online WQA Process Model and may be used by clicking on the figure to open the process model tool online. Figure 1. WQA Process Model

https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/_TeamView_Home.htm WQA Process Model Use Guide 2 March 2024 3 Navigating the Interactive Business Process Diagram This section provides instructions for navigating the online interactive WQA Process Model. The main blocks in the WQA Process Model (Figure 1) represent the WQA processes from R004 as shown below: 4.1 F/PO Develops and Submits QAAP 4.2 NNSA WQD Plans and Conducts WQA Activities 4.3 F/PO Executes to the F/PO QAAP 4.4 Use and Control of NNSA Accepted Product 4.5 F/PO Analyzes WQA Performance Information and Documents Results When a user opens the online WQA Process Model and clicks a main process block, additional interactive blocks open that represent further steps. Figure 2 is an example of the portion of the WQA Process Model that opens when the 4.1: F/PO Develops and Submits QAAP block is clicked. Figure 2. Example of 4.1: F/PO Develops and Submits QAAP WQA Process Model Use Guide 3 March 2024 Some process blocks drill down three or more levels. At the end of each drill-down, the user has access to a property sheet that offers a description for that process step (see Figure 3). Figure 3: Example of Property Sheet (NOTE: Figure is not hyperlinked) WQA Process Model Use Guide 4 March 2024 A block with a folded corner indicates that completion of that process step correlates to meeting an R004 federal requirement (see Figure 4). Figure 4: Folded Corner Example (NOTE: Figure is not hyperlinked) WQA Process Model Use Guide 5 March 2024 4 Weapon Quality Assurance Process This section introduces the top-level representation for each of the five R004 WQA processes as shown in the WQA Process Model (Figure 1 on page 1). Users have two options to open the WQA Process Model: 1. To open the home page, click Weapon Quality Assurance Process Model. 2. To open each individual WQA process, click the process graphic in each of the following sections. Once the interactive model opens in a browser window, users can click each block or icon for additional steps and information. Remember, some process blocks drill down three or more levels. Appendix A lists and provides links to the templates that are used throughout the WQA process. 4.1 F/PO Develops and Submits QAAP Figure 5 graphically represents the blocks and document that open when a user clicks the 4.1 F/PO Develops and Submits a QAAP graphic. Each of these blocks and documents are active and, when clicked, will open their respective property sheet. Figure 5. Section 4.1 Process Steps https://directives.nnsa.doe.gov/product-realization/Weapon_Quality_Assurance_Processes_20240118/_TeamView_Home.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_3b69eed6-cb71-41ab-bc3c-d30fd224eb20_EFFBD_d242252a-5106-46a8-a7d6-a9be72b4aaf2.htm WQA Process Model Use Guide 6 March 2024 4.2 NNSA WQD Plans and Conducts WQA Activities Figure 6 graphically represents the blocks and documents that open when a user clicks the 4.2 NNSA WQD Plans and Conducts WQA Activities graphic. Each of these blocks and documents are active and, when clicked, will open another active block or their respective property sheet. Figure 6. Section 4.2 Process Steps

4.3 F/PO Executes to the F/PO QAAP Figure 7 graphically represents the blocks and documents that open when a user clicks the 4.3 F/PO Executes to the F/PO QAAP graphic. Each of these blocks and documents are active and, when clicked, will open another active block or their respective property sheet. Table 1 following the figure provides links directly to necessary subprocesses used for this process. https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_4d77b8ac-4074-493c-b0a2-1dc469e9c98c_EFFBD_fb66b937-86a5-4118-91ee-7a56c77c7dca.htm WQA Process Model Use Guide 7 March 2024 Figure 7. Section 4.3 Process Steps https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_e8056f54-d940-46af-9bc3-9892eeb60155_EFFBD_330df24f-2f97-491e-ba36-c093c707e249.htm WQA Process Model Use Guide 8 March 2024 Table 1. Section 4.3 Subprocesses Subprocess Title Model Location F/PO Conducts QAS 4.3.1 F/PO Conducts CAVs 4.3.2 F/PO Authorizes M&O Delegated Authority for Verification Inspection and Stamping Activities 4.3.4 PA applies a Diamond Stamp to the product PA.Diamond.Stamp F/PO Conducts Verification Inspections 4.3.7 F/PO makes a Quality Instruction List (QIL) determination 4.3.7.1 F/PO develops Quality Assurance Inspection Procedure (QAIP) 4.3.7.2 F/PO conducts Verification Inspections and Acceptance stamping 4.3.7.3 PA submits product to NNSA for Verification Inspection utilizing a Certificate of Inspection (COI) 4.3.7.3.1 When defects are identified the F/PO originates a Quality Assurance Defect Report (QADR) 4.3.7.3.13.2 PA initiates corrective action response process 4.3.7.3.13.4 F/PO utilizes a Circle T stamp to indicate conditional acceptance 4.3.7.3.13.13 F/PO applies a Diamond Stamp to the product Diamond.Stamp F/PO updates the Summary Log Fully.Accepted.5 https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_0c5bfaa5-e7d6-4398-8c2d-98bb012a310a_EFFBD_503f8ca8-2439-4159-a062-54cbf76591da.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_eabfaaf8-86e7-493c-b8e5-ff0db6d714ff_EFFBD_a22c71a2-ed1f-499b-91dc-1cf7938ac5a3.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_d5db5e42-f81c-4f88-94ea-3420d131b5e6_EFFBD_a522a7dd-4962-41d9-8783-8f313be1525b.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_90f98fb8-dedb-4f47-b93c-283d58e0f64f.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_431f73de-d5d4-41ef-b21e-a26d1c1d3134_EFFBD_fa2f4a20-6905-4abe-a0ca-5f57b125ac89.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_df4c1627-0864-4e30-a8c8-805a80556761_EFFBD_c57912f2-83ea-4607-955a-cbc83df57ea8.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_86ce1196-26e1-4246-8984-607c2c986844.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_0aa7cf94-537c-4675-8fab-a090722b7ee5_EFFBD_64c21e03-ac5d-42c3-90c3-647806a11e60.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_0f11ba53-5a44-443b-9885-bd3a1c33be68_EFFBD_9caf559a-1fba-421d-a2ce-aad346d049de.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_dbf14331-7302-4577-86b4-65e2174aab1c_EFFBD_d4b35686-b9b1-4853-8bce-7ee075ee483a.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_2313b031-dcd1-4c71-b6a8-26032d5ef084_EFFBD_3d0e83fb-9d20-4dca-a8e0-d5be572fa082.htm https://directives.nnsa.doe.gov/product-realization/Weapon_Quality_Assurance_Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_66c7bc47-4cf3-4d06-aead-5c9bd03d19f1_EFFBD_b5d5e1e3-0361-45f9-9322-e81d6196944a.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_b9988fd9-933e-41d8-8e73-566651912bde.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_9d56b63c-8b66-4103-ab0f-f61d644177f8.htm

WQA Process Model Use Guide 9 March 2024 4.4 Use and Control of NNSA Accepted Product Figure 8 graphically represents the blocks and documents that open when a user clicks the 4.4 Use and Control of NNSA Accepted Product graphic. Each of these blocks and documents are active and, when clicked, will open another active block or their respective property sheet. Table 2 following the figure provides links directly to necessary subprocesses used for this process. Figure 8. Section 4.4 Process Steps https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_b0ca8758-78e2-42eb-8efb-38d9e5140e87_EFFBD_1fb5fa4f-f89d-4638-882a-8f6ce755c113.htm WQA Process Model Use Guide 10 March 2024 Table 2. Section 4.4 Subprocesses Subprocess Model Location F/PO applies an IP Stamp to the package label IP.Stamp The PA receives NNSA Accepted product for its intended use 4.4.3 PA receives and controls NNSA Accepted product 4.4.3.1 Suspect NNSA accepted product is identified and notifications are made 4.4.3.1.2 Shipping F/PO manages nonconforming NNSA Accepted product 4.4.3.1.5 F/PO applies a Star Stamp Star.Stamp NNSA product returns from the DOD 4.4.6 F/PO, DA, or PA applies an AR Stamp to the product Acceptance.Required.Stamp F/PO Reaccepts the product 4.4.6.3 F/PO applies a United Kingdom (UK) Stamp U.K.Stamp NNSA product returns from the UK 4.4.8 F/PO, DA, or PA applies a post acceptance diversion stamp to the product Post.Acceptance.Diversion.Stamp https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_8807ee30-8ba2-4642-ad7e-12f075af1224.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_b8aec3c4-9307-4b47-8e34-411dbea6f0c8_EFFBD_ceb10e64-053c-47c0-9081-d8a616e2f2dc.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_94de1fe0-0a55-4826-8015-67b2a126da8a_EFFBD_ae154ddb-8b0a-44be-a1e2-c6be7e2cdf35.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_a4af743b-bfc5-4011-8b59-7848c753b24d_EFFBD_0f2b88f8-34c0-4706-a301-028913ed1f95.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_9c2a7d1f-2d63-4cd4-ad2a-89660a7855a4_EFFBD_cc7188ca-6dbb-4b0a-afe6-9d34d529a768.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_41fc3149-271a-43ae-8da4-f13022b374cb.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_2a9d203e-9ea7-4818-bb66-cdab5febc3d5_EFFBD_a3e1da54-c39a-44e1-b49f-9704160731ba.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_8c84c40f-3e31-4a9a-bcb2-275d2b2e04b3.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_74b3090b-e42b-4950-abab-43dcbc33dc99_EFFBD_20745146-4956-4ed4-b710-9f9dbf374a45.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_820e1c78-61fc-41d2-bac2-d5e5beffecfc.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_249c6078-eb3e-4e2f-81f1-d8d1359c1008_EFFBD_93c65369-cb03-42b0-a6cd-9b7e983aa896.htm https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_e733a05a-70b3-4d43-96d7-a1f4ecd3b965_EFFBD_b32b62e1-8fca-4a24-89ce-c37a65a00833.htm

WQA Process Model Use Guide 11 March 2024 4.5 F/PO Analyzes WQA Performance Information and Documents Results Figure 9 graphically represents the blocks and documents that open when a user clicks the 4.5 F/PO Analyzes WQA Performance Information and Documents Results graphic. Each of these blocks and documents are active and, when clicked, will open another active block or their respective property sheet. Figure 9. Section 4.5 Process Steps https://directives.nnsa.doe.gov/product-realization/Weapon%20Quality%20Assurance%20Processes_20240118/af45a549-05bd-429a-89b9-2f5629d99e51_47d279af-42ef-4b83-b596-2958447148de_EFFBD_013efc1d-183e-4bd3-8203-8bfc00910415.htm WQA Process Model Use Guide 12 March 2024 5 Key Definitions 5.1 WQA Processes Glossary Terms The following terms are for use with this content during review. Term Acronym Definition Source Reason Corrective Action Response CAR A PA documented response to identified nonconforming product that includes the PA investigating the defect to determine the root cause and extent of the nonconformance and the PA developing specific corrective action(s) and/or preventive action(s) to prevent recurrence. WQA Processes New Factual Accuracy A factual accuracy check provides the organization being audited the opportunity to review the information in the draft survey report to determine if the information that is in the survey report is factual. The factual accuracy process also enables the auditors to verify that they have obtained and considered all relevant information that will form the basis of the survey report. WQA Processes New Incidental Defect A defect that does not affect form, fit, function or traceability of the product that has been submitted. This might include cosmetic items or paperwork errors. WQA Processes Revision Incidental Finding Isolated instances of nonconformance that are easily corrected and will not have an immediate impact on cost, performance, or schedule. WQA Processes Revision Open setup The utilization of open setup mechanical M&TE (i.e., inside and outside micrometers, depth micrometer, dial indicators with gage blocks on surface plate, go-no-go gages, calipers etc.) or the utilization of electrical M&TE (i.e., ohm meters for voltage and resistance measurements) for verification activities. WQA Processes New Quality Assurance Survey 1.0 QAS 1 NNSA WQD (or delegate) examines how effectively the F/PO or NNSA contractor implements, monitors, and improves the WQMS and its implementing policies, processes, and procedures, as well as the level of compliance with NNSA Weapon Quality requirements. These are performed on a risk-based frequency. WQA Processes Revision WQA Process Model Use Guide 13 March 2024 Term Acronym Definition Source Reason Quality Assurance Survey 2.0 QAS 2 Whereas a QAS 1 assesses the overall WQMS, a QAS 2 is generally focused on a specific system, weapon program, or major assembly (and various subassemblies). QAS 2s generally include multiple team members. WQA Processes Revision Quality Assurance Survey 3.0 QAS 3 A QAS 3 scope is generally focused on an assembly or component, department, process, or product and is not as broad as a QAS 2. The size of the team depends on the scope of the survey and may include one or more auditors. WQA Processes Revision Quality Assurance Survey 4.0 QAS 4 A QAS 4 scope is generally focused on a specific part, production or inspection operation, or a procedure. WQA Processes

Revision Stage QAIP A product configuration that is desirable to inspect because specific features cannot be inspected at the next/final assembly. WQA Processes Revision 6 Traceability References The following sources are referenced in this content: • R004: Weapon Quality Assurance Processes WQA Process Model Use Guide 14 March 2024 Appendix A: Weapons Quality Assurance Process Templates The templates in Table 3 are used throughout the WQA processes. Each item in the template column links to the named template. Table 3. WQA Process Templates Template Model Location Certificate of Inspection (COI) 4.3.7.3.1.1 Quality Assurance Defect Report (QADR) QADR Summary Log Fully.Accepted.5 NNSA Stamps and Part Marking Various Locations Circle T Plan 4.3.7.3.13.11 Nonconforming Material Report (NMR) 4.4.3.1.5.3 https://directives.nnsa.doe.gov/related-items/certification-of-inspection-template https://directives.nnsa.doe.gov/related-items/template_quality-assurance-defect-report_v0_11062023-1.pdf https://directives.nnsa.doe.gov/related-items/template_summary-log_v0_11062023-1.pdf https://directives.nnsa.doe.gov/related-items/nnsa-stamping-and-part-marking-diagram https://directives.nnsa.doe.gov/related-items/template_circle-t-plan_v0_11062023-1.pdf https://apps.gov.powerapps.us/play/e/fd168cd2-2f11-ea5b-8f6f-b6b8ab3b6551/a/feef5a84-5d3f-4fa5-8065-48569c0571ec?tenantId=6b183ecc-4b55-4ed5-b3f8-7f64be1c4138&hint=769fb690-3940-430b-85cc-b9deba901b74&sourcetime=1718643881013&source=portal 1 Tool Usage 2 Scope 3 Navigating the Interactive Business Process Diagram 4 Weapon Quality Assurance Process 4.1 F/PO Develops and Submits QAAP 4.2 NNSA WQD Plans and Conducts WQA Activities 4.3 F/PO Executes to the F/PO QAAP 4.4 Use and Control of NNSA Accepted Product 4.5 F/PO Analyzes WQA Performance Information and Documents Results 5 Key Definitions 5.1 WQA Processes Glossary Terms 6 Traceability References Appendix A: Weapons Quality Assurance Process Templates