-----------------------------------------------------------------------
  **MSFC PRACA : 2003-02-12 07:54**

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

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

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

+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **In-Flight   | **C       | **      | *    |        |
| Record \#**\ | Anomaly       | ontractor | JSC#**\ | *KSC |        |
| A01589       | Number**\     | Report    | \--     | #**\ |        |
|              | \--           | Number**\ |         | \--  |        |
|              |               | T-007-2   |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| ABLATOR      |               |           |         |      |        |
| MATERIAL NOT |               |           |         |      |        |
| TO SPEC      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Cont    | **F     | **   |        |
| \--          | ET            | ractor**\ | SCM#**\ | FCRI |        |
|              |               | MMMSS     | \--     | T**\ |        |
|              |               |           |         | 3    |        |
+--------------+---------------+-----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc    |         |      |        |
| \--          | N             | Codes**\  |         |      |        |
|              |               | A B       |         |      |        |
|              |               | **(X)** C |         |      |        |
|              |               | D E F G H |         |      |        |
|              |               | I J K L M |         |      |        |
|              |               | N O       |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| EIM          | EXTERNAL      | 82        | VARIOUS | UFAC |        |
|              |               | 601000000 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | MMC  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| LRU          | N/A           | N/A       | N/A     | UFAC |        |
|              |               |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | N/A  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| NCA          | ABLATOR       | STP/PI    | N/A     | UFAC |        |
|              | FORMULATION   | 1508      |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | MMC  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /     | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\      | Mode**\ | Caus |        |
| M - MFG      | \--           | UC        | \--     | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **System**\  | **Defect**\   | **Ma      | **Work  | **   |        |
| THERMAL      | \--           | terial**\ | Con     | Fail |        |
|              |               | \--       | tact**\ | Dat  |        |
|              |               |           | R.      | e**\ |        |
|              |               |           | MELLOR  | 03   |        |
|              |               |           |         | /01/ |        |
|              |               |           |         | 1979 |        |
+--------------+---------------+-----------+---------+------+--------+
| **Received   | **Date        | **FMEA    | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Ref       | Mission | *Mis |        |
| 06/18/1980   | \--           | erence**\ | P       | sion |        |
|              |               | 1.2       | hase**\ | Ela  |        |
|              |               |           | \--     | psed |        |
|              |               |           |         | Tim  |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               | **S       |         | **   |        |
| *Location**\ |               | ymptom**\ |         | Time |        |
| MAF          |               | \--       |         | Cycl |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               |           |         |      |        |
| *Effectivity |               |           |         |      |        |
| Text**\      |               |           |         |      |        |
| ET-3         |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    | **Vehicle     | **Vehicle | **      | *    |        |
| 1**\         | 2**\          | 3**\      | Vehicle | *Veh |        |
| \--          | \--           | \--       | 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**\      | \--           |           | Ac      |      |        |
| \--          |               |           | tion**\ |      |        |
|              |               |           | \--     |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **I          |               |           |         |      |        |
| nvestigation |               |           |         |      |        |
| / Resolution |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer   | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\   | Date**\ | *R/C |        |
| 10/07/1987   | 06/18/1980    | \--       | \--     | Code |        |
|              |               |           |         | s**\ |        |
|              |               |           |         | 2 -  |        |
|              |               |           |         | MFG  |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Assignee** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| B. DAVIS     | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | \--           | D. NEWMAN | G.      | ject |        |
|              |               |           | CA      | MG   |        |
|              |               |           | VALARIS | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Approval** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| B. DAVIS     | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | \--           | D. NEWMAN | J. ODOM | ject |        |
|              |               |           |         | MG   |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC    | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure   | atus**\ | *F/A |        |
| C. NEWTON    | CN            | Date**\   | C -     | C    |        |
|              |               | 0         | CLOSED  | ompl |        |
|              |               | 7/14/1980 |         | etio |        |
|              |               |           |         | n**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    | **SEV**\      | **Program | **      | **O  |        |
| Type**\      | \--           | Name**\   | REVL**\ | PRIN |        |
| \--          |               | \--       | \--     | 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**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **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** |               |           |         |      |        |
|              |               |           |         |      |        |
| REF: MARS    |               |           |         |      |        |
| T20515       |               |           |         |      |        |
| (TYPICAL) &  |               |           |         |      |        |
| CAPS T-007   |               |           |         |      |        |
| (BASIC)      |               |           |         |      |        |
| ABLATOR      |               |           |         |      |        |
| MATERIALS    |               |           |         |      |        |
| FAIL         |               |           |         |      |        |
|              |               |           |         |      |        |
| TO CONFORM   |               |           |         |      |        |
| TO           |               |           |         |      |        |
| S            |               |           |         |      |        |
| PECIFICATION |               |           |         |      |        |
| REQUIREMENTS |               |           |         |      |        |
| FOR          |               |           |         |      |        |
| PHYSICA      |               |           |         |      |        |
| L/MECHANICAL |               |           |         |      |        |
|              |               |           |         |      |        |
| PROPERTIES.  |               |           |         |      |        |
| A. ABLATOR   |               |           |         |      |        |
| FAILS TO     |               |           |         |      |        |
| CONFORM TO   |               |           |         |      |        |
| TEN          |               |           |         |      |        |
| SILE/DENSITY |               |           |         |      |        |
|              |               |           |         |      |        |
| R            |               |           |         |      |        |
| EQUIREMENTS. |               |           |         |      |        |
| B. NUMEROUS  |               |           |         |      |        |
| MACHINING    |               |           |         |      |        |
| ERRORS. C.   |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
|              |               |           |         |      |        |
| APPLICATION/ |               |           |         |      |        |
| DISTRIBUTION |               |           |         |      |        |
| OF MATERIALS |               |           |         |      |        |
| DURING MOLD  |               |           |         |      |        |
| APPLICATION. |               |           |         |      |        |
| D. PART      |               |           |         |      |        |
|              |               |           |         |      |        |
| DAMAGE       |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| IN-HOUSE     |               |           |         |      |        |
| INSPECTION.  |               |           |         |      |        |
| E.           |               |           |         |      |        |
| FACILI       |               |           |         |      |        |
| TY/EQUIPMENT |               |           |         |      |        |
| PROBLEMS     |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| In           |               |           |         |      |        |
| vestigation/ |               |           |         |      |        |
| Resolution** |               |           |         |      |        |
|              |               |           |         |      |        |
| CAUSE: (A)   |               |           |         |      |        |
| IMPROPER     |               |           |         |      |        |
| RE           |               |           |         |      |        |
| SIN/CATALYST |               |           |         |      |        |
| RATION,      |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| CURE OF      |               |           |         |      |        |
| MATERIAL     |               |           |         |      |        |
|              |               |           |         |      |        |
| (THIC        |               |           |         |      |        |
| KNESS-TIME), |               |           |         |      |        |
| INCON-       |               |           |         |      |        |
| SISTENT      |               |           |         |      |        |
| CORK/SILICA  |               |           |         |      |        |
| MICROSPHERE  |               |           |         |      |        |
| SIZING, &    |               |           |         |      |        |
|              |               |           |         |      |        |
| N            |               |           |         |      |        |
| ONHOMOGENOUS |               |           |         |      |        |
| MIXING. (B)  |               |           |         |      |        |
| INCOMPLETE   |               |           |         |      |        |
| TRAINING/CE  |               |           |         |      |        |
| RTIFICATION. |               |           |         |      |        |
| (C) FIRST    |               |           |         |      |        |
|              |               |           |         |      |        |
| PIECE        |               |           |         |      |        |
| C            |               |           |         |      |        |
| ONFIGURATION |               |           |         |      |        |
| INADEQUATE.  |               |           |         |      |        |
| (D)          |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| HANDLING,    |               |           |         |      |        |
|              |               |           |         |      |        |
| PACKA        |               |           |         |      |        |
| GING/STORAGE |               |           |         |      |        |
| OF COMPONENT |               |           |         |      |        |
| PARTS. (E)   |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| MAINTENANCE  |               |           |         |      |        |
| OF           |               |           |         |      |        |
|              |               |           |         |      |        |
| FACILITIES & |               |           |         |      |        |
| EQUIPMENT    |               |           |         |      |        |
| FOR ET RATE. |               |           |         |      |        |
| RESOLUTION:  |               |           |         |      |        |
| ABALATOR     |               |           |         |      |        |
| FORMATIONS   |               |           |         |      |        |
|              |               |           |         |      |        |
| HAVE SHOWN   |               |           |         |      |        |
| SIGNIFICANT  |               |           |         |      |        |
| IMPROVEMENTS |               |           |         |      |        |
| RESULTING    |               |           |         |      |        |
| FROM THE     |               |           |         |      |        |
| FOLLOWING    |               |           |         |      |        |
|              |               |           |         |      |        |
| CLOSURE      |               |           |         |      |        |
| ACTIONS: A1. |               |           |         |      |        |
| A SLA 561    |               |           |         |      |        |
| THICKNESS VS |               |           |         |      |        |
| CURE TIME    |               |           |         |      |        |
| MATRIX HAVE  |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
|              |               |           |         |      |        |
| ESTABLISHED  |               |           |         |      |        |
| &            |               |           |         |      |        |
| INCORPORATED |               |           |         |      |        |
| INTO         |               |           |         |      |        |
| APPROPRIATE  |               |           |         |      |        |
| PROCEDURES   |               |           |         |      |        |
| (REF MEMO    |               |           |         |      |        |
|              |               |           |         |      |        |
| 3            |               |           |         |      |        |
| 612-79-139). |               |           |         |      |        |
| A2. SOP      |               |           |         |      |        |
| 3636-005     |               |           |         |      |        |
| WHICH IS A   |               |           |         |      |        |
| SUPPLEMENT   |               |           |         |      |        |
| TO PI\'S     |               |           |         |      |        |
| 1506,        |               |           |         |      |        |
|              |               |           |         |      |        |
| 1508, 1509,  |               |           |         |      |        |
| & 1510 HAS   |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| VERIFIED &   |               |           |         |      |        |
| ADDED TO THE |               |           |         |      |        |
| PROCEDURES.  |               |           |         |      |        |
| A3. NEW      |               |           |         |      |        |
|              |               |           |         |      |        |
| CAPS T-011 & |               |           |         |      |        |
| T-012        |               |           |         |      |        |
| DEALING WITH |               |           |         |      |        |
| RTV RESINS   |               |           |         |      |        |
| HAS BEEN     |               |           |         |      |        |
| ISSUED &     |               |           |         |      |        |
| WILL TRACK   |               |           |         |      |        |
|              |               |           |         |      |        |
| PROBLEMS     |               |           |         |      |        |
| BETWEEN      |               |           |         |      |        |
| VENDOR & MAF |               |           |         |      |        |
| OPERATIONS.  |               |           |         |      |        |
| B. EMPLOYEE  |               |           |         |      |        |
| TRAINING &   |               |           |         |      |        |
|              |               |           |         |      |        |
| C            |               |           |         |      |        |
| ERTIFICATION |               |           |         |      |        |
| HAS BEEN     |               |           |         |      |        |
| EXPANDED     |               |           |         |      |        |
| FROM 8 TO 30 |               |           |         |      |        |
| HRS WITH     |               |           |         |      |        |
| R            |               |           |         |      |        |
| EVISED/ADDED |               |           |         |      |        |
|              |               |           |         |      |        |
| CLASS WORK & |               |           |         |      |        |
| OJT. (REF    |               |           |         |      |        |
| MMC          |               |           |         |      |        |
| -ET-SE08A-D) |               |           |         |      |        |
| EMPLOYEE     |               |           |         |      |        |
| TRAINING HAS |               |           |         |      |        |
| SHOWN A      |               |           |         |      |        |
|              |               |           |         |      |        |
| MARKED       |               |           |         |      |        |
| IMPROVEMENT  |               |           |         |      |        |
| IN APPLICA-  |               |           |         |      |        |
| TION         |               |           |         |      |        |
| PROCESSES.   |               |           |         |      |        |
| C. MOVEMENT  |               |           |         |      |        |
| OF IN        |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS &    |               |           |         |      |        |
| FINISHED     |               |           |         |      |        |
| PARTS ARE    |               |           |         |      |        |
| NOW BEING    |               |           |         |      |        |
| HANDLED BY   |               |           |         |      |        |
| PRODUCTION   |               |           |         |      |        |
| CONTROL      |               |           |         |      |        |
|              |               |           |         |      |        |
| DEPT. ONLY.  |               |           |         |      |        |
| THIS HAS     |               |           |         |      |        |
| GREATLY      |               |           |         |      |        |
| REDUCED      |               |           |         |      |        |
| HANDLING     |               |           |         |      |        |
| DAMAGE &     |               |           |         |      |        |
| SUBSEQUENT   |               |           |         |      |        |
|              |               |           |         |      |        |
| REWORK,      |               |           |         |      |        |
| FUTURE       |               |           |         |      |        |
| DAMAGE DUE   |               |           |         |      |        |
| TO HANDLING  |               |           |         |      |        |
| WILL BE      |               |           |         |      |        |
| TRACKED ON   |               |           |         |      |        |
| MMC          |               |           |         |      |        |
| CORRECTIVE   |               |           |         |      |        |
|              |               |           |         |      |        |
| ACTION       |               |           |         |      |        |
| DIRECTIVE    |               |           |         |      |        |
| FORM. D.     |               |           |         |      |        |
| MAINTENANCE  |               |           |         |      |        |
| OF           |               |           |         |      |        |
| FACILITIES & |               |           |         |      |        |
| EQUIPMENT    |               |           |         |      |        |
| WILL BE      |               |           |         |      |        |
|              |               |           |         |      |        |
| AN ONGOING   |               |           |         |      |        |
| TASK BUT     |               |           |         |      |        |
| CERTAIN      |               |           |         |      |        |
| ACTIONS HAVE |               |           |         |      |        |
| BEEN TAKEN   |               |           |         |      |        |
| TO DATE      |               |           |         |      |        |
| INCLUDING A  |               |           |         |      |        |
|              |               |           |         |      |        |
| NEW FACILTIY |               |           |         |      |        |
| (BLDG 130).  |               |           |         |      |        |
| REF MEMO     |               |           |         |      |        |
| 3660-79-501  |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       |               |           |         |      |        |
| Response/C   |               |           |         |      |        |
| oncurrence** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+

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

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

  ---------------- ----------------- ---------------- ----------- ----------- ------------
  **MSFC           **IFA#**\         **Contractor     **JSC#**\   **KSC#**\   **EICN#**\
  Report#**\       \--               RPT#**\          \--         \--         \--
  A01589                             T-007-2                                  

  **Asmnt Part#**\ **Asmnt Part      **Asmnt                                  
  \--              Name**\           Serial/Lot#**\                           
                   \--               \--                                      

  **HCRIT CD**\    **FCRIT CD**\     **CAUSE CD**\    **FAIL                  
  \--              \--               \--              MODE**\                 
                                                      \--                     

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

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

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

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

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

  **MAJOR DESIGN                                                              
  CHANGES**                                                                   

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

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