# Presentation: 943991

## NASA Supplier Chain Conference 2007

- REDSTONE Launch

- ORION Launch

- 1959 -2009 Anniversary Logo

- 50 Years of Mission Assurance

- Mission Operations

## Presentation Objective

- To communicate and share with NASA Supplier Partners GSFC Mission On-Orbit performance enhancements so all can achieve higher levels of mission success.
- To provide some practical Engineering tools to get us all there!

- Mission Operations

## NASA Customer Requirements

- Meet and exceed NASA Specification & Standards technical requirements with all deliverables.
- Optimize processes to maximize Safety, Quality, Reliability, Maintainability &  profitability.

**Customer **
**Satisfaction**

**Quality**

**Value**

**Service**

- NASA Crew Exploration Vehicle Module

- Mission Operations

## NASA Supplier Workshop 2007

| Typical Business Loss Symptoms |
| --- |
| 1. High quantity of Product Returns |
| 2. High Product complaints |
| 3. Poor Customer Satisfaction |
| 4. Lost Profits,  Sales, Time & Corporate Image |
| 5. High Warranty Costs |
| 6. Increased Service Calls |
| 7. High number of Engineering Changes (ECOs) |
| 8. Blind-sided adverse events/situations |
| 9. Miss-aligned or missing Quality Barriers |
| 10. Reactive business posture |

- Question:
- Does your organization suffer from any of these classic loss symptoms?

- Mission Operations

## NASA Supplier Workshop 2007

| Typical Business Symptoms | Business Impact | What To Do! |
| --- | --- | --- |
| 1. High quantity of Product Returns | Lost profits | Cause/Effect Analysis  |
| 2. High Product complaints | Lost customer confidence | Root Cause Analysis,
Pareto Analysis, Barrier Analysis (BA) |
| 3. Poor Customer Satisfaction | Lost sales to competition | Measure, Analyze & Fix |
| 4. Lost Profits,  Sales, Time & Corporate Image | High risk producer, High Cost of Sales  | Sell real Quality...Stop burning the toast!  |
| 5. High Warranty Costs | Profit drainer | Use the 5 Why’s (WWWWW) |
| 6. Increased Service Calls | Costly product fixes | Feedback fixes to the Source |
| 7. High number of Engineering Changes (ECOs) | Hidden cost item, band aid fixes | Ship no wine before it‘s time...Test, Test, Test! (Fly Before Buy!) |
| 8. Blind-sided adverse events/situations | SURPRISE!...When you least expect it! | Know your product limits! 
Life testing works! (RIDT) |
| 9. Miss-aligned or missing Quality Barriers | Costly Process flaws | Continuously improve the process...forever! USE BA! |
| 10. Reactive business posture | Knee jerk responses  | Welcome to the NFL! Practice & Plan your offenses! |

- Mission Operations

-  ***What’s Driving NASA GSFC Anomalies***

- Mission Operations

## NASA Supplier Workshop 2007

- A New Approach Primer To Mission Success Using _*Barrier Analysis*_*

- * Definition: Barrier Analysis is an investigation or design method that involves tracing of pathways by which a target is adversely affected by a hazard including any failed or missing countermeasures that could or should have prevented the desired effect (s).

- Mission Operations

## Classic 21st Century... Physical Barriers...we are all familiar with and now take for granted! 

- Local Folks: Wilson Bridge Barrier...
- Jersey Wall...Stevens Institute invention!

- USA Nuclear Plant  Containment

- Volvo Auto Air Bag  Nest System

- Mission Operations

## The Approach: Anomaly Barrier Analysis (ABA)

**The Approach: Anomaly Barrier Analysis (ABA)**

***Anomaly Barrier (s)***
- Requirements
- Quality System
- Quality Support
- Policies
- Procedures
- Inspection/Test
- Screening
- Standards

***Anomaly Source (s)***
- H/W & S/W
- Electrical
- Mechanical
- Operator
- RFI/EMI
- Weather
- Radiation
- Chemical
- Hydraulic
- Pneumatic
- Administrative
- Management
- Knowledge-based
- Policy-based
- Change itself!

- Anomaly

- Mission

- Anomalies

-     Anomalies

***Target (s) at Risk***
- S/C
- Ground Systems
- Communications

**Single-Point Barrier**

- ESCAPES

_*Classical*_
_*Countermeasures*_

- A

- C

- B

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## Cost Analysis: “Lets Stop Burning The Toast” said Dr. Deming!

- Latest Government hardware/software product performance statistics shows that product quality and reliability have gone from bad to worse from 1985 to 1990 (60 good/40 bad) to 1995 to 2000 (20 good /80 bad)!
- We at GSFC have seen orders of magnitude increases in on-orbit anomalies.

- (Ref: *Satellite and launches trend down*, Mario Caceres, Aerospace America Magazine, Jan 04)

**Ave. worldwide failures/satellite in 2001-3 up 56% from the decade before...**

- Mission Operations

## The Mission Assurance Challenge

***Mission Success***

***Establish key repeatable Space Vehicle Verification Processes***

- Acquisition Reform

** ****System of Systems**
**  ****Complexity and Net **
**  ****Centricity**
** ****Acquisition Practices**
**  ****& Rise of Consumer **
**  ****Electronic**
** ****Vehicle Complexity**

**Increasingly Complex Environment**

**GOAL:**
**Increasing Mission Success**

**Avoid **
**Mission Success Erosion**

- Today

**Mission Success**

*Time*

- Source: Mission Assurance End Game: Lt .Col. Susan Hastings, NRO/DSIE, QLF (5/07) Boulder , Colo.

- Mission Operations

## NASA GSFC On-orbit Anomalies 

|  | Missions | S/C Anomalies | GS/Com Anomalies |
| --- | --- | --- | --- |
| 1982 |  |  |  |
| 1983 | 16 | 67* |  |
| 1984 |  |  |  |
| 1985 |  |  |  |
| 1986 | 20 | 37 |  |
| 1987 | 23 | 56 |  |
| 1988 |  |  |  |
| 1989 |  |  |  |
| 1990 |  |  |  |
| 1991 |  |  |  |
| 1992 |  |  |  |
| 1993 |  |  |  |
| 1994 |  |  |  |
| 1995 |  |  |  |
| 1996 | 31 | 180 | 301 |
| 1997 | 34 | 125 | 325 |
| 1998 |  |  |  |
| 1999 |  |  |  |
| 2000 |  |  |  |
| 2001 |  |  |  |
| 2002 |  |  |  |
| 2003 | 56 | 554 | 1420 |
| 2004 |  |  |  |
| 2005 |  |  |  |
| 2006 |  |  |  |
| 2007 | 40 | 607 | 2025 |

- annualized

- NASA GSFC On-orbit Anomalies
- Source: Annual OAGS Reports

- Mission Operations

## Mission Success Tools & Techniques

**Applying Multiple Quality Barriers****Rx**** for Total Mission Success**

- Basic
- Level I

- Level III
- Mission Success

- Level II
- Aerospace

- First line of Defense

- 2nd Level of Defense

- 3rd Level of Defense
**Superior Anomaly Target**
**Interdiction**

- Anomalies

- Mission Operations

## Mission Success Tools & Techniques

- Mission
- Success

- Procedures

- Policy

- Surveillance

- Exhibit A.  Defect Prevention, Interdiction, Detection, & Containment

- Barriers:
- Level I

- Barriers
- Level II

**Gaps**

**Gaps**

- Training

- Requirements

- Testing

- AS9000

- Reviews

- Support

- Standards

- Certification

- Mission Operations

## Mission Success Tools & Techniques

**Barriers: Level I**

**Barriers:**
**Level II**

**Barriers: Level III**

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## NASA GSFC OSSMA Mission Operations

- Defect Prevention, Interdiction, Detection and Containment

**Lesson Learned From Analyzing 20,000 GSFC Anomalies**

**Eliminating all gaps/escapes!**

- Remember the Matador!

- In 1953, the USAF Project officer wrote that the Matador Program was delayed excessively because of poor design, inadequate testing, and difficulty in retaining qualified people."

- " Throughout its service, observers criticized the Matador for its low in-flight reliability, high CEPs, and questionable control over long distances. A 1956 study noted that USAF did not develop Matador according to procedures and military requirements, but rather devised the missile around existing components and techniques.

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## Slide 17

| TOP 10 Suppliers Actions to Improve Mission Success |
| --- |
| 1. Screen your parts – validate your source of supply, inspect, test, burn-in, qualify, re-qualify, package, handling, storage, shipping & transportation.    |
| 2. Train your personnel – Workmanship, Soldering, Cable Harness, Polymerics, ESD, Fiber-optics, Repair & Rework, Environmental GEVS, new NASA-STD-1000 & 8739 Series. |
| 3. Understand NASA Requirements & Flowdown to Suppliers – Environmental GEVS, AS9100, SEI CMM/CMMI, AIAA-2007-1629, S R M & QA, NASA Golden Rules & Avoid FOD!  |
| 4. Trust, But Verify – It  worked for Reagan! – Do assessments, pre-award surveys, Surveys, Peer Reviews, Recordkeeping, evidence of test, compliance to requirements. Validations & Verifications.   |
| 5. TEST, TEST, TEST – Remember HST SM No. 1 successes!   End-to-End and full up ATPs work best!  Qualification, Reliability, MIL-STD-1540, AIAA 2007-1630, “Test Like You Fly (TLYF)!” |
| 6. Control the Process – Map it...Six-Sigma tools work...use KISS techniques too! |
| 7. Communicate with your NASA Partner – What is the application of your product? |
| 8 .Get Engaged with Quality Resources – CQSDI, RAMS, PBMA, QLF, ASQ, INCOSE, IEEE, AIAA. Become a Quality Champion! |
| 9. Use WIN WIN formula...everybody loves a Winner! Success is contagious! Successes brings additional successes!  |
| 10. Improve your systems & processes forever!  Dr. Deming’s Legacy to America! |

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## Top 10 Supplier Actions for Mission Success

***#10. Improve The System Forever!***
*We, together, have the talent/technology to be the Best of the Best!*
*Join the NASA Contractor Quality Renaissance!*

- Dr. Deming’s Legacy to America!

- His “*14 Step Program for World Class Business Survival”* is 27 years old now!

- Mission Operations

## Top 10 Supplier Actions for Mission Success

***#9 Play Win Win with NASA and your Supplier Chain!***
-  Repeated successes brings everyone rewards and profitable challenges!

- Look at the Great Programs from 1959 to Date!
- Mercury, Gemini, Apollo, Shuttle (STS) and now on to Orion and Beyond!

- _[  ](http://history.nasa.gov/40thmerc7/bios.htm)__      _            _[Carpenter](http://history.nasa.gov/40thmerc7/carpenter.htm)__       __[Cooper](http://history.nasa.gov/40thmerc7/cooper.htm)__       __[Glenn](http://history.nasa.gov/40thmerc7/glenn.htm)__       __[Grissom](http://history.nasa.gov/40thmerc7/grissom.htm)__ __       __[Schirra](http://history.nasa.gov/40thmerc7/schirra.htm)__       __[Shepard](http://history.nasa.gov/40thmerc7/shepard.htm)__       __[Slayton](http://history.nasa.gov/40thmerc7/slayton.htm)_

- Mission Operations

## Top 10 Supplier Actions for Mission Success

***#8. Stay Engaged with NASA....Quality Champions are needed.... ***
*The 21**st** Century Quality Bandwagon is on the road...you are invited to join us now!*
*Don’t get left behind!*

- CQSDI Conferences, Quality Leadership Forum (QLF), NASA PBMA, NASA Mission Success Workshops, ASQ, IEEE, INCOSE & AIAA

- Mission Operations

- Our USA Race to Space is Not Over!
- Lets change “the cheapest bidder” to the “Best of the Best”!

*Top 10 Supplier Actions for Mission Success*

***#7 Communicate with your NASA partners! ***
*What is the NASA application your product? Of your supplier’s products?*

- Mission Operations

***#6 Control the process!***
- Map it out...use tools like Six-Sigma (6Σ)
- KISS too, still  works!
- See Bob run w/6Σ!
-      Note: Old Forge, PA coal cracker native!

- _[  ](http://www.6sigma.us/dmaic-step-zero-leadership.php)_

*Top 10 Supplier Actions for Mission Success*

- Mission Operations

***#5. TEST, TEST...***
***TEST!***
- Remember HST SM #1!
- End To End...Full-Up ATPs work best!
- TEST AS YOU FLY!

- _[  ](http://www.6sigma.us/dmaic-step-zero-leadership.php)_

*Top 10 Supplier Actions for Mission Success*

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## Top 10 Supplier Actions for Mission Success

*Top 10 Supplier Actions for Mission Success*

***#4. TRUST, But Validate & Verify!***
*It worked for President Reagan...and US! *

- Mission Operations

## Top 10 Supplier Actions for Mission Success

*Top 10 Supplier Actions for Mission Success*

***#3. Understand NASA Requirements & Flowdown to your suppliers!***
** ****From FAR 1846 to the new Golden Rules (NASA STD-1000) to GEVS!**
** ****See NASA SMARTS Library on line at NASA HQ site!**
** ****Avoid FOD!**

- Web Addresses:
- http://www.nasa.gov/audience/forindustry/home/index.html
- _[http://nodis3.gsfc.nasa.gov/lib_docs.cfm?range=1___](http://nodis3.gsfc.nasa.gov/lib_docs.cfm?range=1___)_

- Mission Operations

## Top 10 Supplier Actions for Mission Success

***#******2. TRAIN Personnel!***
- Workmanship, Soldering, Cable Harness, Polymerics, ESD, Repair & Rework, Fiber Optics!
- New NASA STD-8739 Series Procedures.
- New NASA-STD-1000.
- Web-site: http://workmanship.nasa.gov

- _[NASA Safety & Mission Success Requirements (Safety, Reliability, Maintainability, and Quality Doc. Tree)](http://www.hq.nasa.gov/office/codeq/doctree/doctreec.htm)_
- _[NASA Headquarters Office of Safety and Mission Assurance (OSMA)](http://www.hq.nasa.gov/office/codeq)__ _
- _[NASA Site for Online Learning and Resources (SOLAR)](https://solar.msfc.nasa.gov/solar/delivery/public/html/)__ _
- _[NASA Technical Standards Program](http://standards.nasa.gov/)__ _
**	**_[Marshall Space Flight Center (MSFC) Engineering Directorate](http://ed.msfc.nasa.gov/)_
- _[Process Based Mission Assurance (PBMA)](http://pbma.hq.nasa.gov/index2.html)__ _
- _[Countdown Video Magazine](http://www.countdownonline.tv/countdown.html)__ _**- focused on raising awareness of Space Shuttle related process control and safety issues **
- _[The Nondestructive Evaluation Sciences Branch at NASA Langley Research Center (LaRC)](http://nesb.larc.nasa.gov/index.html)_** **

-  _[NASA Quality Program](http://quality.nasa.gov/)__ _
-  _[Lessons Learned Information System (LLIS)](http://llis.nasa.gov/)_
-  _[NASA EEE Parts Assurance Group (NEPAG) ](http://eee.larc.nasa.gov/forum/Default_2.htm)_
-  _[NASA Electronic Parts and Packaging Program (NEPP)](http://nepp.nasa.gov/)__ _
-  _[EEE Links Newsletter; The official Newsletter for the NEPP Program ](http://nepp.nasa.gov/index_nasa.cfm/787/)_
-  _[NASA Online Directives Information System (NODIS)](http://nodis.gsfc.nasa.gov/library/main_lib.html)__[ ](http://nodis.gsfc.nasa.gov/library/main_lib.html)_

- Mission Operations

## Top 10 Supplier Actions for Mission Success

***#1 Screen All Parts***!
-  Validate your sources of supply
-  Inspect, Test, Burn-in, Qualify, Delid (DPA) & LPD (PIN) all still  work!
-  Check Packaging, Handling, Storage, Shipping and Transportation

**Vision for Space Exploration**

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## Future Missions 

- Future Missions

- Mission Operations

## NASA Supplier Chain Workshop 2007

**Barrier Analysis Quotient (BAQ**) **Exercise**
***Case History No. 19:  Federal High Technology Agency***
***Situation****:*  An older, governmental agency is about to try to transform it’s operation and infra-structure to address new short and long term goals quite unlike present product venues.
- The new direction is one of difficult environmental challenges using products with “ultra-reliability” performance (useful lifetimes of 10 years or greater).
- Presently the agency involves a ISO 9000 Certified Quality Program that, even after several years and millions invested, does not seem to have bought any appreciable differences in product quality levels.  On the contrary, quality levels seem to be degrading and end user performance is not living up to standards or expectations.
***Task at hand:***
- Your job is to look at performing two Barrier Analysis:
- 1. What the quality function (BAQ) needs to be for the future work.
- 2. What the present BAQ is now! And how to get it to where it needs to be.
**Note** on doing this BAQ Exercise: Use your ISO/AS Survey questions as criteria for coming up with questions for each element.  Let your Quality Manager know the results and tell him to fill in the gaps so you can prevent the typical business symptoms from hurting your profitability!

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## NASA GSFC Supplier Chain Workshop 2007Exercise: What should the future systems BAQ score be?

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## NASA Supplier Chain Workshop: What is your present BAQ?

- Use:
-  Green for ok
-  Yellow for needs fixing
-  Red  for broken

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## Top 10 Supplier Actions for Mission Success

- 1."Create constancy of purpose towards improvement". Replace short-term reaction with long-term planning. 2."Adopt the new philosophy". The implication is that management should actually adopt his philosophy, rather than merely expect the workforce to do so. 3."Cease dependence on inspection". If variation is reduced, there is no need to inspect manufactured items for defects, because there won't be any. 4."Move towards a single supplier for any one item." Multiple suppliers mean variation between feedstocks. 5."Improve constantly and forever". Constantly strive to reduce variation. 6."Institute training on the job". If people are inadequately trained, they will not all work the same way, and this will introduce variation. 7."Institute leadership". Deming makes a distinction between leadership and mere supervision. The latter is quota- and target-based. 8."Drive out fear". Deming sees management by fear as counter- productive in the long term, because it prevents workers from acting in the organization's best interests. 9."Break down barriers between departments". Another idea central to TQM is the concept of the 'internal customer', that each department serves not the management, but the other departments that use its outputs. 10."Eliminate slogans". Another central TQM idea is that it's not people who make most mistakes - it's the process they are working within. Harassing the workforce without improving the processes they use is counter-productive. 11."Eliminate management by objectives". Deming saw production targets as encouraging the delivery of poor-quality goods. 12."Remove barriers to pride of workmanship". Many of the other problems outlined reduce worker satisfaction. 13."Institute education and self-improvement". 14."The transformation is everyone's job".

***Top 10 Supplier Actions for Mission Success***

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## Chuck O’Boyle has 20 years U.S. Government service (18 at NASA and 2 in the US Army Ordnance Guided Missile School in Huntsville, Al).   

- Prior to his NASA experience, Chuck was Quality Assurance Director at Kollsman Instruments, Quality Engineering Manager at Martin Marietta, Operations Manager at Teledyne and QA & Reliability Manager at Sanders Associates (ex-Lockheed Martin, now BEA).  Early in his career, he worked as a Sr. Engineer for the Hewlett-Packard Company specializing in microwave instrumentation.
- Chuck worked on the Pershing, Patriot, Titan, B1-B, M60 Tank Fire Control System, Tomahawk, Harpoon, USAF F-111 & US NAVY ALQ-126 Electronic Countermeasures Systems & Nike Ajax/ Hercules Guided Missile Systems.  At NASA, he worked close to 100 successful missions including HST SM # 1 - 3A,  JWST, GRO, XTE, EOS AQUA, AURA & TERRA, TRMM, LandSat 7 &  International Space Station Fluids & Combustion Facility receiving numerous NASA Achievement Awards for his engineering/management contributions and efforts.  The HST QE Team he managed won 16 NASA Medallions for their work on the highly successful Servicing Mission No. 1 Repair Mission.
- For the past several years, as a ManTech SRS Lead Engineer, he supported GSFC Mission Operations for the Office of Mission Assurance covering all GSFC on-orbit mission performance.
- Chuck taught part-time at the Graduate School level in the Boston area for 10 years and is a Honors Graduate of Northeastern University BS & AS and Babson College MBA.  He is also a graduate of both Martin Marietta and Unisys Advanced Management Programs.  And he is a member of Sigma Epsilon Rho National Honor Society.
_***Jim Suraci***__ _  has 25 years experience in the Aerospace, Electronics, Automotive Transportation and Major Appliances industries.  He has developed and implemented effective method for improving Quality, Productivity and Profits.  He is engaged in all aspects of Mission Operations Assurance as well as supporting numerous other GSFC and NASA Quality, Flight, System Engineering and Engineering organizations.
- He has worked as a hands-on contributor for many NASA Projects as an in-plant resident at GE Valley Forge, PA and RCA East Windsor, NJ.  His 25 years Aerospace experience in SRM & QA  Flight and Systems Assurance roles provides NASA with a Best-in-Class viewpoint for all life cycle phases from the design, build, test and integration phases; right up to launch and post launch operations.
- Jim currently tracks the progress of all active Goddard missions and provides support for anomaly review board activities. Jim has extensive interfaces with all Goddard engineering functions and has been central in providing value added feedback to development projects.
- Jim worked as a Sr. Systems Engineer on AQUA, AURA, JWST, and the International Space Station Fluids & Combustion Facility.  He provided Flight Assurance support on TRMM, TERRA GOES, NOAA 15 - 19, LandSat,  DSCS, Wind, Polar and provided valuable support that enabled the latest GSFC OAGS Reports to be generated in short order.
- A graduate of SUNY Buffalo and the GE Manufacturing Management Program, Jim is certified in all NASA Workmanship areas.   Jim has also worked for General Electric and Unisys in a variety of Management, Quality and engineering positions.  Jim is a Boy Scout Troop Leader in BSA Troop 406 in Royersford, PA. He is the proud father of two Eagle Scout sons one on academic scholarship at Rensselaer Polytechnic University and the other at Temple University.

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## References:

_*Out of the Crises*_ by Dr. Edward Deming 1982
_*Space Vehicle Systems & Engineering Handbook*_ by Aerospace Corporation 2006
_*Rules for Design, Development, Verification & Operation of Flight Systems*_ by NASA GSFC-STD-1000 December 10, 2004
_*The Six-Sigma Way*_ by Pande, Newman & Cavanaugh McGraw Hill, NY  2000
_*Implementation of Revitalized Engineering Specifications & Standards for National Security Space Programs*_ by Meshel, Hastings, Blackman, Davis, Tosney & Knight AIAA 2007-1629
_*Development Of a Space Vehicle Test & Evaluation Handbook*_ by Peterson, Hanifen & Tosney Aerospace Corporation and Lt. Col. Susan E. Hastings,  NRO AIAA 2007-1630

*Top 10 Supplier Actions for Mission Success*

_*Hazard & Barrier Analysis Guidance Document*_ ( EH 33) by the DOE Office of Operating Experience Analysis & Feedback Nov 1996
_*Barrier Analysis Guidance*_  - web-site https://sbms.bnl.gov/SBMSearch/subjarea/39/2m04e011.doc
- ISO Information:
- http://ts.nist.gov/Standards/Global/ir4721.cfm

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