-----------------------------------------------------------------------
  **MSFC PRACA : 2003-02-12 08:41**

  -----------------------------------------------------------------------

  -----------------------------------------------------------------------
  MSFC Problem Reporting and Corrective Action (PRACA) System

  WHOLE RECORD REPORT( + ADDENDUM)
  -----------------------------------------------------------------------

+--------------+---------------+----------+---------+------+--------+
| **MSFC       | **In-Flight   | **Co     | **      | *    |        |
| Record \#**\ | Anomaly       | ntractor | JSC#**\ | *KSC |        |
| A17395       | Number**\     | Report   | \--     | #**\ |        |
|              | \--           | N        |         | \--  |        |
|              |               | umber**\ |         |      |        |
|              |               | E-166    |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Problem    |               |          |         |      |        |
| Title**\     |               |          |         |      |        |
| AFT          |               |          |         |      |        |
| SRB/ORBITER  |               |          |         |      |        |
| WIRE HARNESS |               |          |         |      |        |
| (303W04)     |               |          |         |      |        |
| FAILED       |               |          |         |      |        |
| DIELECTRIC   |               |          |         |      |        |
| WITHSTAND    |               |          |         |      |        |
| VOLTAGE      |               |          |         |      |        |
| (1500) TEST  |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Contr  | **F     | **   |        |
| \--          | ET            | actor**\ | SCM#**\ | FCRI |        |
|              |               | LMMSS    | \--     | T**\ |        |
|              |               |          |         | 1R   |        |
+--------------+---------------+----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc   |         |      |        |
| \--          | \--           | Codes**\ |         |      |        |
|              |               | A B C D  |         |      |        |
|              |               | E F G H  |         |      |        |
|              |               | I J K L  |         |      |        |
|              |               | M N O    |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| *            | **NO          | **       | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | PART#**\ | LOT#**\ | *MAN |        |
| EIM          | \--           | \--      | \--     | UFAC |        |
|              |               |          |         | TURE |        |
|              |               |          |         | R**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| *            | **NO          | **       | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | PART#**\ | LOT#**\ | *MAN |        |
| LRU          | \--           | \--      | \--     | UFAC |        |
|              |               |          |         | TURE |        |
|              |               |          |         | R**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| *            | **NO          | **       | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | PART#**\ | LOT#**\ | *MAN |        |
| NCA          | 303W04 WIRE   | 0        | 800780  | UFAC |        |
|              | HARNESS       | 3714-160 |         | TURE |        |
|              |               |          |         | R**\ |        |
|              |               |          |         | L    |        |
|              |               |          |         | MMSS |        |
+--------------+---------------+----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /    | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\     | Mode**\ | Caus |        |
| A - ATP      | F -           | F        | EL -    | e**\ |        |
|              | FUNCTIONAL    |          | SHORT   | M -  |        |
|              |               |          |         | MA   |        |
|              |               |          |         | NUFG |        |
+--------------+---------------+----------+---------+------+--------+
| **System**\  | **Defect**\   | **Mat    | **Work  | **   |        |
| ELECTRICAL   | \--           | erial**\ | Con     | Fail |        |
|              |               | \--      | tact**\ | Dat  |        |
|              |               |          | J.      | e**\ |        |
|              |               |          | VA      | 04   |        |
|              |               |          | RRIELLO | /20/ |        |
|              |               |          |         | 1999 |        |
+--------------+---------------+----------+---------+------+--------+
| **Received   | **Date        | **FMEA   | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Refe     | Mission | *Mis |        |
| 04/22/1999   | 04/20/1999    | rence**\ | P       | sion |        |
|              |               | 3.12.4.2 | hase**\ | Ela  |        |
|              |               |          | \--     | psed |        |
|              |               |          |         | Tim  |        |
|              |               |          |         | e**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| *            |               | **Sy     |         | **   |        |
| *Location**\ |               | mptom**\ |         | Time |        |
| MAF          |               | EL -     |         | Cycl |        |
|              |               | SHORT    |         | e**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| *            |               |          |         |      |        |
| *Effectivity |               |          |         |      |        |
| Text**\      |               |          |         |      |        |
| ET 104       |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Vehicle    |               |          |         |      |        |
| Effectivity  |               |          |         |      |        |
| Codes**      |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Vehicle    | **Vehicle     | *        | **      | *    |        |
| 1**\         | 2**\          | *Vehicle | Vehicle | *Veh |        |
| \--          | \--           | 3**\     | 4**\    | icle |        |
|              |               | \--      | \--     | 5**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| **Mission    |               |          |         |      |        |
| Effectivity  |               |          |         |      |        |
| Codes**      |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Mssn 1**\  | **Mssn 2**\   | **Mssn   | **Mssn  | **   |        |
| \--          | \--           | 3**\     | 4**\    | Mssn |        |
|              |               | \--      | \--     | 5**\ |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| **Estimated  |               |          |         |      |        |
| Completion   |               |          |         |      |        |
| Dates**      |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **MSFC       | **Contractor  | **LVL 3  | *       |      |        |
| Approved     | Req Defer     | Close**\ | *Remark |      |        |
| Defer Until  | Until Date**\ | \--      | /       |      |        |
| Date**\      | 05/15/1999    |          | Ac      |      |        |
| 09/07/1999   |               |          | tion**\ |      |        |
|              |               |          | 05/     |      |        |
|              |               |          | 15/1999 |      |        |
+--------------+---------------+----------+---------+------+--------+
| **I          |               |          |         |      |        |
| nvestigation |               |          |         |      |        |
| / Resolution |               |          |         |      |        |
| Summary**    |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer  | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\  | Date**\ | *R/C |        |
| 06/28/1999   | \--           | 05       | 04/     | Code |        |
|              |               | /04/1999 | 22/1999 | s**\ |        |
|              |               |          |         | \--  |        |
|              |               |          |         | \--  |        |
|              |               |          |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| **Assignee** |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Design**\  | **Chief       | **S &    | **Pro   | *    |        |
| J. RATLEY    | Engineer**\   | MA**\    | ject**\ | *Pro |        |
|              | J. LUSK       | J. GREEN | \--     | ject |        |
|              |               |          |         | MG   |        |
|              |               |          |         | R**\ |        |
|              |               |          |         | P.   |        |
|              |               |          |         | CO   |        |
|              |               |          |         | UNTS |        |
+--------------+---------------+----------+---------+------+--------+
| **Approval** |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Design**\  | **Chief       | **S &    | **Pro   | *    |        |
| J. RATLEY    | Engineer**\   | MA**\    | ject**\ | *Pro |        |
|              | J. LUSK       | A. ADAMS | \--     | ject |        |
|              |               |          |         | MG   |        |
|              |               |          |         | R**\ |        |
|              |               |          |         | P.   |        |
|              |               |          |         | CO   |        |
|              |               |          |         | UNTS |        |
+--------------+---------------+----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC   | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure  | atus**\ | *F/A |        |
| R. TUCKER    | RT            | Date**\  | C -     | C    |        |
|              |               | 06       | CLOSED  | ompl |        |
|              |               | /23/1999 |         | etio |        |
|              |               |          |         | n**\ |        |
|              |               |          |         | 04   |        |
|              |               |          |         | /29/ |        |
|              |               |          |         | 1999 |        |
+--------------+---------------+----------+---------+------+--------+
| **Problem    | **SEV**\      | *        | **      | **O  |        |
| Type**\      | \--           | *Program | REVL**\ | PRIN |        |
| \--          |               | Name**\  | \--     | C**\ |        |
|              |               | \--      |         | \--  |        |
+--------------+---------------+----------+---------+------+--------+
| **FUNC       | **Software    | **       |         | **SU | **So   |
| MOD**\       | E             | Software |         | BTYP | ftware |
| \--          | ffectivity**\ | Fail     |         | E**\ | C      |
|              | \-- \-- \--   | CD**\    |         | \--  | losure |
|              | \-- \--       | \--      |         |      | CD**\  |
|              |               |          |         |      | \--    |
+--------------+---------------+----------+---------+------+--------+
| **RES PERSON | **Approval    |          |         |      |        |
| L2**\        | Signature     |          |         |      |        |
| \--          | L3**\         |          |         |      |        |
|              | \--           |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    | **Related     |          |         |      |        |
| Document     | Document      |          |         |      |        |
| Type**\      | ID**\         |          |         |      |        |
| \--          | N040378       |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    |               |          |         |      |        |
| Document     |               |          |         |      |        |
| Title**\     |               |          |         |      |        |
| \--          |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    | **Related     |          |         |      |        |
| Document     | Document      |          |         |      |        |
| Type**\      | ID**\         |          |         |      |        |
| \--          | \--           |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    |               |          |         |      |        |
| Document     |               |          |         |      |        |
| Title**\     |               |          |         |      |        |
| \--          |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    | **Related     |          |         |      |        |
| Document     | Document      |          |         |      |        |
| Type**\      | ID**\         |          |         |      |        |
| \--          | \--           |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Related    |               |          |         |      |        |
| Document     |               |          |         |      |        |
| Title**\     |               |          |         |      |        |
| \--          |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Contractor |               |          |         |      |        |
| Status       |               |          |         |      |        |
| Summary**    |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Reliabi    |               |          |         |      |        |
| lity/Quality |               |          |         |      |        |
| Assurance    |               |          |         |      |        |
| Concerns,    |               |          |         |      |        |
| Recomm       |               |          |         |      |        |
| endations:** |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Problem    |               |          |         |      |        |
| D            |               |          |         |      |        |
| escription** |               |          |         |      |        |
|              |               |          |         |      |        |
| PROBLEM      |               |          |         |      |        |
|              |               |          |         |      |        |
| THE WIRE     |               |          |         |      |        |
| HARNESS      |               |          |         |      |        |
| FAILED THE   |               |          |         |      |        |
| POST         |               |          |         |      |        |
| INSTALLATION |               |          |         |      |        |
| TM04         |               |          |         |      |        |
| DIELECTRIC   |               |          |         |      |        |
|              |               |          |         |      |        |
| WITHSTAND    |               |          |         |      |        |
| VOLTAGE      |               |          |         |      |        |
| (1500 V)     |               |          |         |      |        |
| TEST AT MAF  |               |          |         |      |        |
|              |               |          |         |      |        |
| CRITICALITY: |               |          |         |      |        |
| THE 303W04   |               |          |         |      |        |
| WIRE HARNESS |               |          |         |      |        |
| IS CRIT. 1R; |               |          |         |      |        |
| FMEA ITEM    |               |          |         |      |        |
|              |               |          |         |      |        |
| CODE:        |               |          |         |      |        |
| 3.12.4.2,    |               |          |         |      |        |
| \"FAILS      |               |          |         |      |        |
| SHORTED\"    |               |          |         |      |        |
|              |               |          |         |      |        |
| PREVIOUS     |               |          |         |      |        |
| CAPS: E-24,  |               |          |         |      |        |
| E-68, E-80,  |               |          |         |      |        |
| E-107,       |               |          |         |      |        |
| E-128,       |               |          |         |      |        |
| E-148, E-164 |               |          |         |      |        |
|              |               |          |         |      |        |
| REVISION     |               |          |         |      |        |
| \'A\' IS     |               |          |         |      |        |
| DATED        |               |          |         |      |        |
| 05/15/1999   |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **Contractor |               |          |         |      |        |
| In           |               |          |         |      |        |
| vestigation/ |               |          |         |      |        |
| Resolution** |               |          |         |      |        |
|              |               |          |         |      |        |
| GENERAL:     |               |          |         |      |        |
|              |               |          |         |      |        |
| THE AFT      |               |          |         |      |        |
| SRB/ORBITER  |               |          |         |      |        |
| CABLE        |               |          |         |      |        |
| (303W04) ON  |               |          |         |      |        |
| ET-104 WAS   |               |          |         |      |        |
| BEING TESTED |               |          |         |      |        |
|              |               |          |         |      |        |
| IN FINAL     |               |          |         |      |        |
| ASSEMBLY AT  |               |          |         |      |        |
| MAF. THE     |               |          |         |      |        |
| TESTS        |               |          |         |      |        |
| INCLUDE A    |               |          |         |      |        |
| 500 VOLT     |               |          |         |      |        |
|              |               |          |         |      |        |
| INSULATION   |               |          |         |      |        |
| RESISTANCE   |               |          |         |      |        |
| (IR) TEST    |               |          |         |      |        |
| AND A 1500   |               |          |         |      |        |
| VOLT         |               |          |         |      |        |
| DIELECTRIC   |               |          |         |      |        |
|              |               |          |         |      |        |
| WITHSTANDING |               |          |         |      |        |
| VOLTAGE TEST |               |          |         |      |        |
| FOLLOWED BY  |               |          |         |      |        |
| ANOTHER 500  |               |          |         |      |        |
| VOLT IR TEST |               |          |         |      |        |
|              |               |          |         |      |        |
| OF EVERY     |               |          |         |      |        |
| CIRCUIT IN   |               |          |         |      |        |
| THE CABLES.  |               |          |         |      |        |
| THE HARNESS  |               |          |         |      |        |
| HAD A        |               |          |         |      |        |
| RESISTANCE   |               |          |         |      |        |
|              |               |          |         |      |        |
| LESS THAN    |               |          |         |      |        |
| THE MINIMUM  |               |          |         |      |        |
| ACCEPTABLE   |               |          |         |      |        |
| VALUE OF 2   |               |          |         |      |        |
| MEGOHMS AT   |               |          |         |      |        |
| 1500         |               |          |         |      |        |
|              |               |          |         |      |        |
| VOLTS        |               |          |         |      |        |
| REQUIRED BY  |               |          |         |      |        |
| TEST         |               |          |         |      |        |
| PROCEDU      |               |          |         |      |        |
| RE-6C101-FA. |               |          |         |      |        |
| THE FAILURE  |               |          |         |      |        |
|              |               |          |         |      |        |
| OCCURRED     |               |          |         |      |        |
| BETWEEN      |               |          |         |      |        |
| CONTACT      |               |          |         |      |        |
| 303W04J04-H  |               |          |         |      |        |
| AND ET       |               |          |         |      |        |
| STRUCTURE    |               |          |         |      |        |
| GROUND       |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK I       |               |          |         |      |        |
| FAI          |               |          |         |      |        |
| LURE/PROBLEM |               |          |         |      |        |
| I            |               |          |         |      |        |
| NVESTIGATION |               |          |         |      |        |
|              |               |          |         |      |        |
| A. THE CABLE |               |          |         |      |        |
| WILL BE      |               |          |         |      |        |
| REMOVED FROM |               |          |         |      |        |
| ET-104 AND   |               |          |         |      |        |
| FAILURE      |               |          |         |      |        |
| ANALYSIS     |               |          |         |      |        |
|              |               |          |         |      |        |
| WILL BE      |               |          |         |      |        |
| PERFORMED BY |               |          |         |      |        |
| RELIABILITY  |               |          |         |      |        |
| ASSURANCE    |               |          |         |      |        |
|              |               |          |         |      |        |
| RES          |               |          |         |      |        |
| PONSIBILITY: |               |          |         |      |        |
|              |               |          |         |      |        |
| J.           |               |          |         |      |        |
| VARRIELLO -  |               |          |         |      |        |
| 3741/ D.     |               |          |         |      |        |
| WESTPHAL -   |               |          |         |      |        |
| 3740         |               |          |         |      |        |
|              |               |          |         |      |        |
| ECD:         |               |          |         |      |        |
| 05/20/1999   |               |          |         |      |        |
|              |               |          |         |      |        |
| COMPLETED:   |               |          |         |      |        |
| 04/29/1999   |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK CLOSED  |               |          |         |      |        |
|              |               |          |         |      |        |
| SINCE THE    |               |          |         |      |        |
| FACT         |               |          |         |      |        |
| ANALYZER     |               |          |         |      |        |
| FOUND THE    |               |          |         |      |        |
| FAILURE WAS  |               |          |         |      |        |
| \"H\" TO ET  |               |          |         |      |        |
|              |               |          |         |      |        |
| STRUCTURE IN |               |          |         |      |        |
| FINAL        |               |          |         |      |        |
| ASSEMBLY,    |               |          |         |      |        |
| THE INITIAL  |               |          |         |      |        |
| I            |               |          |         |      |        |
| NVESTIGATION |               |          |         |      |        |
| WAS          |               |          |         |      |        |
|              |               |          |         |      |        |
| FOCUSED ON   |               |          |         |      |        |
| THIS         |               |          |         |      |        |
| SCENARIO.    |               |          |         |      |        |
| THE HARNESS  |               |          |         |      |        |
| WAS MOVED TO |               |          |         |      |        |
| HARNESS      |               |          |         |      |        |
|              |               |          |         |      |        |
| FABRICATION  |               |          |         |      |        |
| AREA, AND    |               |          |         |      |        |
| TP-6C143-HA  |               |          |         |      |        |
| WAS          |               |          |         |      |        |
| PERFORMED    |               |          |         |      |        |
| USING THE    |               |          |         |      |        |
| FACT         |               |          |         |      |        |
|              |               |          |         |      |        |
| ANALYZER TO  |               |          |         |      |        |
| EXECUTE      |               |          |         |      |        |
| ACCEPTANCE   |               |          |         |      |        |
| TESTS FOR    |               |          |         |      |        |
| 1500 DWV,    |               |          |         |      |        |
| CONTINUITY,  |               |          |         |      |        |
|              |               |          |         |      |        |
| AND 500 IR.  |               |          |         |      |        |
| THE HARNESS  |               |          |         |      |        |
| PASSED ALL   |               |          |         |      |        |
| TESTS. THE   |               |          |         |      |        |
| FAILURE OF   |               |          |         |      |        |
| \"H\"        |               |          |         |      |        |
|              |               |          |         |      |        |
| TO OVS/ET    |               |          |         |      |        |
| STRUCTURE    |               |          |         |      |        |
| GROUND COULD |               |          |         |      |        |
| NOT BE       |               |          |         |      |        |
| DUPLICATED   |               |          |         |      |        |
|              |               |          |         |      |        |
| DURING       |               |          |         |      |        |
| VISUAL       |               |          |         |      |        |
| INSPECTION   |               |          |         |      |        |
| OF THE OVS,  |               |          |         |      |        |
| A DISCREPANT |               |          |         |      |        |
| AREA OF      |               |          |         |      |        |
|              |               |          |         |      |        |
| FRAYED       |               |          |         |      |        |
| DAMAGE WAS   |               |          |         |      |        |
| FOUND ABOUT  |               |          |         |      |        |
| 92.5 INCHES  |               |          |         |      |        |
| FROM THE     |               |          |         |      |        |
| POTTED       |               |          |         |      |        |
|              |               |          |         |      |        |
| BACKSHELL OF |               |          |         |      |        |
| 303W04P44.   |               |          |         |      |        |
| THE OVS WAS  |               |          |         |      |        |
| REMOVED AND  |               |          |         |      |        |
| FURTHER      |               |          |         |      |        |
|              |               |          |         |      |        |
| VISUAL       |               |          |         |      |        |
| EXAMINATION  |               |          |         |      |        |
| IN THE AREA  |               |          |         |      |        |
| WHERE THE    |               |          |         |      |        |
| OVS WAS      |               |          |         |      |        |
| DAMAGED      |               |          |         |      |        |
|              |               |          |         |      |        |
| REVEALED A   |               |          |         |      |        |
| SMALL SPLIT  |               |          |         |      |        |
| IN ONE OF    |               |          |         |      |        |
| THE          |               |          |         |      |        |
| UNDERLYING   |               |          |         |      |        |
| KAPTON(R)    |               |          |         |      |        |
|              |               |          |         |      |        |
| WRAPPED      |               |          |         |      |        |
| CONDUCTORS.  |               |          |         |      |        |
| THIS SINGLE  |               |          |         |      |        |
| CONDUCTOR    |               |          |         |      |        |
| (            |               |          |         |      |        |
| 303W04J04-H) |               |          |         |      |        |
| WAS          |               |          |         |      |        |
|              |               |          |         |      |        |
| CONNECTED TO |               |          |         |      |        |
| A BIDDLE,    |               |          |         |      |        |
| AND VOLTAGE  |               |          |         |      |        |
| WAS          |               |          |         |      |        |
| INCREASED TO |               |          |         |      |        |
| 1000V        |               |          |         |      |        |
|              |               |          |         |      |        |
| ATTACHING A  |               |          |         |      |        |
| 3-INCH PIECE |               |          |         |      |        |
| OF COPPER    |               |          |         |      |        |
| BRAID TO THE |               |          |         |      |        |
| GROUND LEAD  |               |          |         |      |        |
|              |               |          |         |      |        |
| FROM THE     |               |          |         |      |        |
| BIDDLE AND   |               |          |         |      |        |
| ALLOWING IT  |               |          |         |      |        |
| TO BRUSH     |               |          |         |      |        |
| AGAINST THE  |               |          |         |      |        |
| DEFECT       |               |          |         |      |        |
|              |               |          |         |      |        |
| AREA         |               |          |         |      |        |
| RESULTED IN  |               |          |         |      |        |
| AN ARCING    |               |          |         |      |        |
| SPARK FROM   |               |          |         |      |        |
| THE COPPER   |               |          |         |      |        |
| BRAID TO THE |               |          |         |      |        |
|              |               |          |         |      |        |
| CHARRED      |               |          |         |      |        |
| SPLIT        |               |          |         |      |        |
|              |               |          |         |      |        |
| MICROSCOPIC  |               |          |         |      |        |
| EXAMINATION  |               |          |         |      |        |
| OF THE       |               |          |         |      |        |
| \"CHARRED    |               |          |         |      |        |
| SPLIT\"      |               |          |         |      |        |
| FOUND THAT   |               |          |         |      |        |
| IT           |               |          |         |      |        |
|              |               |          |         |      |        |
| WAS A SLICE  |               |          |         |      |        |
| IN THE       |               |          |         |      |        |
| KAPTON(R)    |               |          |         |      |        |
| WIRE         |               |          |         |      |        |
| EXTENDING    |               |          |         |      |        |
| A            |               |          |         |      |        |
| PPROXIMATELY |               |          |         |      |        |
| HALF         |               |          |         |      |        |
|              |               |          |         |      |        |
| WAY AROUND   |               |          |         |      |        |
| THE WIRE,    |               |          |         |      |        |
| AND THE      |               |          |         |      |        |
| \"CHARRED    |               |          |         |      |        |
| SPLIT\" WAS  |               |          |         |      |        |
| CLEARLY A    |               |          |         |      |        |
|              |               |          |         |      |        |
| PUNCTURE     |               |          |         |      |        |
| THROUGH ALL  |               |          |         |      |        |
| LAYERS OF    |               |          |         |      |        |
| KAPTON(R)    |               |          |         |      |        |
| INSULATION   |               |          |         |      |        |
| EXTENDING    |               |          |         |      |        |
|              |               |          |         |      |        |
| INTO THREE   |               |          |         |      |        |
| OF THE       |               |          |         |      |        |
| NICKEL       |               |          |         |      |        |
| PLATED       |               |          |         |      |        |
| COPPER       |               |          |         |      |        |
| STRANDS.     |               |          |         |      |        |
| REFERENCE    |               |          |         |      |        |
|              |               |          |         |      |        |
| FAILURE      |               |          |         |      |        |
| ANALYSIS     |               |          |         |      |        |
| REPORT       |               |          |         |      |        |
| N021019      |               |          |         |      |        |
|              |               |          |         |      |        |
| B. MEET WITH |               |          |         |      |        |
| THE          |               |          |         |      |        |
| PRODUCTION   |               |          |         |      |        |
| OPERATION    |               |          |         |      |        |
| MANAGERS TO  |               |          |         |      |        |
| DISCUSS      |               |          |         |      |        |
|              |               |          |         |      |        |
| IMPORTANCE   |               |          |         |      |        |
| OF PROPER    |               |          |         |      |        |
| HANDLING OF  |               |          |         |      |        |
| FLIGHT       |               |          |         |      |        |
| HARDWARE     |               |          |         |      |        |
| DURING       |               |          |         |      |        |
|              |               |          |         |      |        |
| MANUFACTURE, |               |          |         |      |        |
| TRA          |               |          |         |      |        |
| NSPORTATION, |               |          |         |      |        |
| AND          |               |          |         |      |        |
| INSTALLATION |               |          |         |      |        |
| AND TO       |               |          |         |      |        |
|              |               |          |         |      |        |
| DETERMINE    |               |          |         |      |        |
| MOST         |               |          |         |      |        |
| EFFECTIVE    |               |          |         |      |        |
| WAY TO       |               |          |         |      |        |
| INFORM       |               |          |         |      |        |
| TECHNICIANS  |               |          |         |      |        |
|              |               |          |         |      |        |
| RES          |               |          |         |      |        |
| PONSIBILITY: |               |          |         |      |        |
|              |               |          |         |      |        |
| J.           |               |          |         |      |        |
| VARRIELLO -  |               |          |         |      |        |
| 3741 / D.    |               |          |         |      |        |
| WESTPHAL -   |               |          |         |      |        |
| 3740         |               |          |         |      |        |
|              |               |          |         |      |        |
| A. PANKS -   |               |          |         |      |        |
| 3671 / M.    |               |          |         |      |        |
| JAVERY -     |               |          |         |      |        |
| 3680         |               |          |         |      |        |
|              |               |          |         |      |        |
| ECD:         |               |          |         |      |        |
| 05/10/1999   |               |          |         |      |        |
|              |               |          |         |      |        |
| COMPLETED:   |               |          |         |      |        |
| 05/07/1999   |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK CLOSED  |               |          |         |      |        |
|              |               |          |         |      |        |
| A MEETING OF |               |          |         |      |        |
| THE AREA     |               |          |         |      |        |
| PRODUCTION   |               |          |         |      |        |
| OPERATIONS   |               |          |         |      |        |
| MANAGEMENT   |               |          |         |      |        |
| AND          |               |          |         |      |        |
|              |               |          |         |      |        |
| QUALITY      |               |          |         |      |        |
| CONTROL      |               |          |         |      |        |
| MANAGEMENT   |               |          |         |      |        |
| WAS HELD,    |               |          |         |      |        |
| AND IT WAS   |               |          |         |      |        |
| AGREED THAT  |               |          |         |      |        |
| A            |               |          |         |      |        |
|              |               |          |         |      |        |
| RETRAINING   |               |          |         |      |        |
| SESSION WITH |               |          |         |      |        |
| EACH         |               |          |         |      |        |
| PRODUCTION   |               |          |         |      |        |
| OPERATIONS   |               |          |         |      |        |
| TECHNICIAN   |               |          |         |      |        |
|              |               |          |         |      |        |
| WAS REQUIRED |               |          |         |      |        |
| TO PREVENT   |               |          |         |      |        |
| FUTURE       |               |          |         |      |        |
| OCCURRENCES  |               |          |         |      |        |
| OF THIS      |               |          |         |      |        |
| ISSUE        |               |          |         |      |        |
|              |               |          |         |      |        |
| THIS WAS     |               |          |         |      |        |
| ACCOMPLISHED |               |          |         |      |        |
| VIA CREW     |               |          |         |      |        |
| MEETINGS.    |               |          |         |      |        |
| (REF: EMAIL  |               |          |         |      |        |
| FROM A       |               |          |         |      |        |
|              |               |          |         |      |        |
| PANKS, DEPT. |               |          |         |      |        |
| 3671)        |               |          |         |      |        |
|              |               |          |         |      |        |
| CAUSE        |               |          |         |      |        |
|              |               |          |         |      |        |
| MISHANDLING  |               |          |         |      |        |
| OF HARNESS   |               |          |         |      |        |
| WHICH        |               |          |         |      |        |
| DAMAGED THE  |               |          |         |      |        |
| WIRE,        |               |          |         |      |        |
| KAPTON(R)    |               |          |         |      |        |
|              |               |          |         |      |        |
| INSULATION,  |               |          |         |      |        |
| AND OVS      |               |          |         |      |        |
| RESULTING IN |               |          |         |      |        |
| THE (1500 V) |               |          |         |      |        |
| DWV FAILURE  |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK II      |               |          |         |      |        |
| CORRECTIVE   |               |          |         |      |        |
| ACTION       |               |          |         |      |        |
|              |               |          |         |      |        |
| ALL          |               |          |         |      |        |
| TECHNICIANS  |               |          |         |      |        |
| IN HARNESS   |               |          |         |      |        |
| FABRICATION  |               |          |         |      |        |
| AND FINAL    |               |          |         |      |        |
| ASSEMBLY     |               |          |         |      |        |
| WERE         |               |          |         |      |        |
|              |               |          |         |      |        |
| WALKED       |               |          |         |      |        |
| THROUGH THE  |               |          |         |      |        |
| EXACT CAUSE  |               |          |         |      |        |
| OF THE       |               |          |         |      |        |
| FAILURE AND  |               |          |         |      |        |
| RE-          |               |          |         |      |        |
|              |               |          |         |      |        |
| INSTRUCTED   |               |          |         |      |        |
| ON THE       |               |          |         |      |        |
| IMPORTANCE   |               |          |         |      |        |
| OF CARE      |               |          |         |      |        |
| DURING       |               |          |         |      |        |
| HANDLING OF  |               |          |         |      |        |
| ALL          |               |          |         |      |        |
|              |               |          |         |      |        |
| ELECTRICAL   |               |          |         |      |        |
| HARNESSES TO |               |          |         |      |        |
| MINIMIZE THE |               |          |         |      |        |
| POSSIBILITY  |               |          |         |      |        |
| OF           |               |          |         |      |        |
| UNDETECTED   |               |          |         |      |        |
|              |               |          |         |      |        |
| DAMAGE TO    |               |          |         |      |        |
| THE HARDWARE |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK CLOSED  |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK III     |               |          |         |      |        |
| CLEARANCE OF |               |          |         |      |        |
| E            |               |          |         |      |        |
| FFECTIVITIES |               |          |         |      |        |
|              |               |          |         |      |        |
| ALL ET\'S    |               |          |         |      |        |
| CLEARED. ALL |               |          |         |      |        |
| ET\'S        |               |          |         |      |        |
| SUCCESSFULLY |               |          |         |      |        |
| PASSED THE   |               |          |         |      |        |
| TM04         |               |          |         |      |        |
|              |               |          |         |      |        |
| DIELECTRIC   |               |          |         |      |        |
| WITHSTAND    |               |          |         |      |        |
| VOLTAGE      |               |          |         |      |        |
| FINAL        |               |          |         |      |        |
| ACCEPTANCE   |               |          |         |      |        |
| TEST         |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK CLOSED  |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK IV CAPS |               |          |         |      |        |
| CLOSURE      |               |          |         |      |        |
| SUMMARY      |               |          |         |      |        |
|              |               |          |         |      |        |
| DURING       |               |          |         |      |        |
| TESTING OF   |               |          |         |      |        |
| SRB WIRE     |               |          |         |      |        |
| HARNESS      |               |          |         |      |        |
| (303W04) IN  |               |          |         |      |        |
| FINAL        |               |          |         |      |        |
| ASSEMBLY,    |               |          |         |      |        |
|              |               |          |         |      |        |
| A FAILURE OF |               |          |         |      |        |
| CONTACT      |               |          |         |      |        |
| \"H\" TO ET  |               |          |         |      |        |
| STRUCTURE    |               |          |         |      |        |
| OCCURRED     |               |          |         |      |        |
| DURING THE   |               |          |         |      |        |
|              |               |          |         |      |        |
| 1500 DWV     |               |          |         |      |        |
| TEST. THE    |               |          |         |      |        |
| WIRE HARNESS |               |          |         |      |        |
| PASSED THE   |               |          |         |      |        |
| FIRST 500    |               |          |         |      |        |
| VDC IR       |               |          |         |      |        |
|              |               |          |         |      |        |
| TEST, FAILED |               |          |         |      |        |
| THE 1500 DWV |               |          |         |      |        |
| TEST, AND    |               |          |         |      |        |
| THEN PASSED  |               |          |         |      |        |
| THE          |               |          |         |      |        |
| SUBSEQUENT   |               |          |         |      |        |
|              |               |          |         |      |        |
| 500 VDC IR   |               |          |         |      |        |
| TEST. THE    |               |          |         |      |        |
| HARNESS WAS  |               |          |         |      |        |
| REMOVED AND  |               |          |         |      |        |
| REPLACED     |               |          |         |      |        |
|              |               |          |         |      |        |
| VISUAL       |               |          |         |      |        |
| INSPECTION   |               |          |         |      |        |
| FOUND AN     |               |          |         |      |        |
| AREA OF      |               |          |         |      |        |
| FRAYED       |               |          |         |      |        |
| DAMAGE ON    |               |          |         |      |        |
| THE OVS      |               |          |         |      |        |
|              |               |          |         |      |        |
| ABOUT 92.5   |               |          |         |      |        |
| INCHES FROM  |               |          |         |      |        |
| THE POTTED   |               |          |         |      |        |
| BACKSHELL OF |               |          |         |      |        |
| 303W04P44.   |               |          |         |      |        |
| THE          |               |          |         |      |        |
|              |               |          |         |      |        |
| CAUSE WAS    |               |          |         |      |        |
| FOUND TO BE  |               |          |         |      |        |
| A SLICE IN A |               |          |         |      |        |
| SINGLE       |               |          |         |      |        |
| CONDUCTOR    |               |          |         |      |        |
|              |               |          |         |      |        |
| (            |               |          |         |      |        |
| 303W04J04-H) |               |          |         |      |        |
| UNDERNEATH   |               |          |         |      |        |
| THE DAMAGED  |               |          |         |      |        |
| AREA OF OVS  |               |          |         |      |        |
|              |               |          |         |      |        |
| P            |               |          |         |      |        |
| RACTITIONERS |               |          |         |      |        |
| WERE BRIEFED |               |          |         |      |        |
| ON THE CAUSE |               |          |         |      |        |
| OF THE       |               |          |         |      |        |
| FAILURE AND  |               |          |         |      |        |
| RE-          |               |          |         |      |        |
|              |               |          |         |      |        |
| INSTRUCTED   |               |          |         |      |        |
| OF THE       |               |          |         |      |        |
| IMPORTANCE   |               |          |         |      |        |
| OF CARE      |               |          |         |      |        |
| DURING       |               |          |         |      |        |
| HANDLING OF  |               |          |         |      |        |
| ALL          |               |          |         |      |        |
|              |               |          |         |      |        |
| ELECTRICAL   |               |          |         |      |        |
| HARNESSES TO |               |          |         |      |        |
| MINIMIZE THE |               |          |         |      |        |
| POSSIBILITY  |               |          |         |      |        |
| OF           |               |          |         |      |        |
| UNDETECTED   |               |          |         |      |        |
|              |               |          |         |      |        |
| DAMAGE TO    |               |          |         |      |        |
| THE HARDWARE |               |          |         |      |        |
|              |               |          |         |      |        |
| TASK CLOSED  |               |          |         |      |        |
|              |               |          |         |      |        |
| THIS CAPS IS |               |          |         |      |        |
| CLOSED. NO   |               |          |         |      |        |
| FURTHER      |               |          |         |      |        |
| ACTION IS    |               |          |         |      |        |
| REQUIRED     |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+
| **MSFC       |               |          |         |      |        |
| Response/C   |               |          |         |      |        |
| oncurrence** |               |          |         |      |        |
|              |               |          |         |      |        |
| 05/04/99 -   |               |          |         |      |        |
| MSFC         |               |          |         |      |        |
| APPROVES     |               |          |         |      |        |
| CLOSED WITH  |               |          |         |      |        |
| ACTION       |               |          |         |      |        |
| STATUS. THIS |               |          |         |      |        |
| STATUS IS    |               |          |         |      |        |
|              |               |          |         |      |        |
| EFFECTIVE    |               |          |         |      |        |
| THROUGH      |               |          |         |      |        |
| 09/07/99     |               |          |         |      |        |
|              |               |          |         |      |        |
| 06/23/99 -   |               |          |         |      |        |
| MSFC CONCURS |               |          |         |      |        |
| WITH CLOSURE |               |          |         |      |        |
| RATIONALE.   |               |          |         |      |        |
| THIS PR IS   |               |          |         |      |        |
| CLOSED       |               |          |         |      |        |
+--------------+---------------+----------+---------+------+--------+

  -----------------------------------------------------------------------
  MSFC Problem Reporting and Corrective Action (PRACA) System

  ASSESSMENT ADDENDUM REPORT
  -----------------------------------------------------------------------

  ----------------- ---------------------- ---------------- ----------- ----------- ------------
  **MSFC Report#**\ **IFA#**\              **Contractor     **JSC#**\   **KSC#**\   **EICN#**\
  A17395            \--                    RPT#**\          \--         \--         \--
                                           E-166                                    

  **Asmnt Part#**\  **Asmnt Part Name**\   **Asmnt                                  
  80931003714-160   303W04 WIRE HARNESS    Serial/Lot#**\                           
                                           800780                                   

  **HCRIT CD**\     **FCRIT CD**\          **CAUSE CD**\    **FAIL                  
  \--               1R                     M - MANUFG       MODE**\                 
                                                            EL - SHORT              

  **Asmnt FMEA**\   **Asmnt FM**\          **FMEA CSE**\    **FMEA                  
  3.12.4.2          \--                    \--              SCSE**\                 
                                                            \--                     

  **Asmnt FMEA**\   **Asmnt FM**\          **FMEA CSE**\    **FMEA                  
  \--               \--                    \--              SCSE**\                 
                                                            \--                     

  **Asmnt FMEA**\   **Asmnt FM**\          **FMEA CSE**\    **FMEA                  
  \--               \--                    \--              SCSE**\                 
                                                            \--                     

  **Correlated      **Correlated Part#**\  **Correlated                             
  Part#**\          \--                    Part#**\                                 
  \--                                      \--                                      

  **Associated      **Associated LRU#**\   **Associated                             
  LRU#**\           \--                    LRU#**\                                  
  \--                                      \--                                      

  **MAJOR DESIGN                                                                    
  CHANGES**                                                                         

  **APRV DATE**\    **DESCRIPTION OF                                                
  \--               CHANGES**\                                                      
                    \--                                                             

  **ASSESSMENT                                                                      
  TEXT**                                                                            
  ----------------- ---------------------- ---------------- ----------- ----------- ------------