ial 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 Grummans 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 BMPs 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 Northrop Grumman Corporation
i
C o n t e n t s
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 Northrop Grumman Corporation
ii
C o n t e n t s
(Continued)
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 Managers 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 Northrop Grumman Corporation
iii
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
F i g u r e s 1
S e c t i o n 1
Report Summary
Background
The Northrop Grumman Corporation can trace
its history back through the pioneering founders of
aviation Jack Northrop, the Loughead [
sic] broth-
ers, Donald Douglas, and Leroy Grumman, to name
a few. Over the years, the company transformed
itself from an airplane manufacturer into a premier
electronics and systems integration corporation.
Today, Northrop Grumman is a leading designer,
systems integrator, and manufacturer of military
surveillance and combat aircraft; defense electron-
ics and systems; airspace management systems;
information systems; marine systems; precision
weapons; space systems; and commercial and mili-
tary aerostructures.
With its corporate headquarters in Los Angeles,
California, Northrop Grumman is organized into
five divisions, employs 52,000 personnel, and
achieved $9.2 billion in sales for 1997. The BMP
survey focused on Northrop Grumman's Military
Aircraft Systems Division which employs 14,000
personnel, encompasses 320 acres, and achieved
$2.6 billion in sales for 1997. This Division, based in
El Segundo, California, is a world-class leader in the
manufacture of military aircraft and unmanned
airborne vehicles; systems integration and engi-
neering research and development; aerostructure
modifications; and upgrades to military air vehicles.
Although Northrop Grumman was recently sur-
veyed by BMP in October 1997, this survey focused
on the environmental practices of the Military Air-
craft Systems Division. Among the best practices
documented were Northrop Grumman's elimina-
tion of ozone depleting chemicals; work in process
cans; chemical tracking system; and Title V operat-
ing permits program.
As the principal subcontractor to Boeing (for-
merly McDonnell Douglas), Northrop Grumman
produces the center and aft fuselage sections; the
twin vertical stabilizers; and all associated sub-
systems for the U.S. Navy F/A-18 Hornet strike
fighter. The F/A-18 production line is housed in the
world's longest, all-wooden building. Constructed
entirely of redwood, the 0.5-mile long F/A-18 assem-
bly building still reflects its World War II design of
a l