Lockheed Martin / Certified Steel H/T Process Control Management Awareness

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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
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
Intertank

LH2 Tank (Welded Pressure Vessel)
Liquid Hydrogen Tank
231,000 lbs. Fuel Temperature -423 Degrees
Fahrenheit Delivery Rate 47,125 Gallons /
Minute
Carries all Shuttle Loads at Liftoff
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
External Tank Components
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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 lines

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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 (contd)
• 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 - dont.
• 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
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The Process Creep
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
People
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
Methods/Instructions
Processes are performed under the proper
environmental conditions (e.g. temperature,
humidity, clean room, lighting, etc.).
Environment
Processes are performed using the correct
equipment (e.g., tooling, Special Test /
Inspection Equipment, etc.)
Equipment
Both product and process/manufacturing
materials must be controlled Substitution
Obsolescence
Materials
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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.
Hazard
Design
Design
Processes
Processes
Manufacturing
Manufacturing
Test
Test
But reality often looks like this.
Source James Reason, Managing the Risks of
Organizational Accidents, 1997, p. 9
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When Events Line Up Just Right, the Consequences
Can Be Devastating
Requirements
Hazard
Design
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
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How do we manage the inevitable changes?

• Guard against design and process creep
• No creep needs to be
• the culture
• Use process control standards and practices
• When change is necessary, report it immediately
  to your customer
• No change is too small to report

Manage change through effective process
control principles.

• Make changes as seamless
• as possible drop in solutions
• preferred
• Participate in the change
• verification process

• Think out-of-the box to
• identify the unknown
• unknowns

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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)
• Higher customer satisfaction
• Bottom Line Always be aware of any process
  changes that deviate from the customer approved
  procedures.

Eliminate these and production rates increase
which adds to the bottom line.
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Lockheed Martin / Certified Steel H/T Process
Control Management Awareness
Greg Harbaugh - Astronaut
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