Transcript Forward SRB Fitting Technical Interchange

Lockheed Martin / Certified Steel H/T Process Control
Management Awareness
Space Shuttle
External Tank
Sub tier Heat Treater
Presenter
William Fisher LMMSS
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
External Tank Components
Liquid Oxygen Tank
Intertank
Liquid
Hydrogen
Tank
LO2 Tank (Welded Pressure Vessel)
• 1,385,000 lbs. Oxidizer
• Temperature = -297 Degrees Fahrenheit
• Delivery Rate = 17,656 Gallons / Minute
Intertank (Riveted Structure)
• Splice ET LO2 and LH2 Tanks
LH2 Tank (Welded Pressure Vessel)
•
•
•
231,000 lbs. Fuel
Temperature = -423 Degrees Fahrenheit
Delivery Rate = 47,125 Gallons / Minute
Carries all Shuttle Loads at Liftoff
Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
External Tank Components
Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
External Tank Information
• Structural backbone of the vehicle
- Absorbs 6.6 million pounds of thrust loads at launch
• 154 feet long; 27.5 feet diameter
• Weight (Loaded) = 1,676,000 Pounds
• Propellant feed rate = 1,035 gallons per second
- It takes 8 1/2 minutes to empty.
• Thickness is approximately .080 in some areas
• Moves really fast !! = 10 x M-16 speeding bullet!
From Meggitt Thermal Systems (Avica) Prime Supplier
Hardware: PD4800180 G02 PD4800205 GH2 Pressurization
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Lockheed Martin / Certified Steel H/T Process Control
Management Awareness
Process Control
• Essential element of managing risk to guarantee
the continued safety and reliability of the Space
Shuttle Program
• Process Control measures can aid in the
prevention of process escapes (Process Creep)
which may result in, or contribute to, in-flight
anomalies, mishaps, incidents and
nonconformance's
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
Process Control Best Practices
• 1) Early Detection of Variability
– Examples – Statistical Process Control, Material Fingerprinting
• 2) Audits (Practice = Instructions)
– Examples – Quality System Audits, Product / Process Integrity Audit,
NASA Engineering and Quality Audit
• 3) Maintenance to Mitigate Process Risks
– Examples – Failure Modes and Effects Analysis (FEMA)
• 4) Lessons Learned / Critical Characteristic Process Control
– Examples – Product Fact sheets
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
Process Control Best Practices (cont’d)
• 5) Personal Accountability
– Examples – Stamp Warranty
• 6) Motivational Programs
– Examples – Space Flight Awareness Program (SFA), Video,
Brochures and posters, Motivational Visits
• 7) Change Control
– Examples – E 43 clause
• 8) Maintaining Process Knowledge / Skill
– Examples – Training and certification
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
STAMP WARRANTY
• Stamp (or signature) MUST be a professional, individual warranty
(guarantee) that the operator/inspector PERSONALLY saw or
performed the work LITERALLY as stated in the work instructions.
– If work instructions are incorrect, unclear, out of sequence or
unverifiable - report them for correction.
– If you are not trained/certified/authorized to perform a function
- don’t.
– YOU have the responsibility and authority to implement stamp
warranty.
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Lockheed Martin / Certified Steel H/T Process Control
Management Awareness
Process Control
• Video Presentation Choose from one of the following
• “Changes”
• Process Control
– “Know Change”
– “Knowledge”
– “Gets us There”
_“To The Future”
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The Process Creep
Methods/Instructions
People
Materials
Equipment
Environment
The Process Creep
The Process Creep
People
Methods/Instructions
Appropriate technical skill level, training and certification,
understand the importance of process and change control:
Example: H.T. Time, Temperature and Solutions, etc.
Stamp Warranty: Legacy Knowledge
The techniques used to perform a process including the
step-by-step documentation or recipe used by a process
operator or technician to accomplish a process
Processes performed in house;
AMS 6875 H.T. of Raw Steel Materials
10S078 Precipitation H.T. (Meggitt)
AMS 2750 Pyometry
Environment
Equipment
Materials
Processes are performed under the proper
environmental conditions (e.g. temperature, humidity,
clean room, lighting, etc.).
Processes are performed using the correct equipment
(e.g., tooling, Special Test / Inspection Equipment, etc.)
Both product and process/manufacturing
materials must be controlled; Substitution;
Obsolescence
Lockheed Martin / Certified Steel H/T Process Control
Heat Treat Related Issues & Impact
Issue: Under and Over Aging of Material
–
Lack of Load Thermocouple
–
Incomplete Contract Review
–
No Final Review of Certification
–
Inadequate Work Instruction for Fabrication
& Inspection of T/Cs
–
Inadequate Planning Review and Approval
–
Inadequate Personnel Training
–
Inadequate Subtier Controls
–
Lack of Attention to Detail at Prime
Supplier During Receipt of Hardware &
Certification
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Defenses Are Never Perfect
We perceive our
ideal system of
defenses like
this.
Design
Hazard
Design
Processes
Processes
Manufacturing
Test
Manufacturing
Test
But reality
often looks
like this.
Source: James Reason, Managing the Risks of Organizational Accidents, 1997, p. 9
When Events Line Up Just Right, the
Consequences Can Be Devastating
Requirements
Design
Hazar
d
Process Development
Manufacturing
Test
Operations
Early Detection,
Communication and
Effective Prevention are Essential
Mishap
Adapted from : James Reason, Managing the Risks of Organizational Accidents, 1997, p. 12
How do we manage the inevitable changes?
 Guard against design and
process creep
Manage change through
effective process control
principles.
 No creep needs to be
the “culture”
 Use process control
standards and practices
 Make changes as seamless
as possible – drop in solutions
preferred
 Participate in the change
verification process
 When change is
necessary, report it
immediately to your
customer
 No change is too small to
report
C
E
 Think out-of-the box to
identify the unknown
unknowns
Does process control make business sense?
• The bottom line to the bottom line – Processes
that are in control produce products that have:
 Fewer non-conformances (eliminate
non-productive resources to disposition)
 Less scrap (reduce material cost)
 Less rework (eliminate non-productive
rework costs)
Eliminate these and
production rates
increase which adds to
the bottom line.
 Higher customer satisfaction
 Bottom Line: Always be aware of any process changes
that deviate from the customer approved procedures.
Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
"We are trusting your
commitment to excellence."
Greg Harbaugh - Astronaut
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