The mission of the Process Control Focus Group is to reduce risk to the Space Shuttle Program by
reducing and/or eliminating process escapes.
Welcome to the Space Shuttle Process Control Focus Group
Focus
There are only a few flights remaining before the Space Shuttle Program comes to an end.
Although the workforce is faced with distractions daily, we must be diligent and focused
on the task at hand to ensure a safe and successful completion. The Ares 1-X test flight
launched on October 28, 2009 and represents the transition to a new space exploration program
know as the Constellation Program. The dedication of the workforce to ensure safety and
process control are key components for the success of both programs.
The Process Control Focus Group has developed a series of posters entitled Commitment, Distraction, Focus, and Responsibility in addition to two short videos featuring Mr. John Shannon, NASA Space Shuttle Program Manager and Ms. Peggy Whitson, NASA Astronaut. These products are provided at no cost to the Space Shuttle Program workforce and are an invaluable resource to communicate the importance of process control so visit www.CountdownOnline.tv and submit your request.
Remember, Process Control Gets Us There!
Process Control
What is it? Process Control consists of the systems and tools used to ensure that processes are well defined,
performed correctly, and maintained so that the completed product conforms to established requirements.
Process Control is an essential element of managing risk to ensure the safety and reliability of the Space
Shuttle Program. It is recognized that strict process control practices will aid in the prevention of process
escapes that may result in or contribute to in-flight anomalies, mishaps, incidents and nonconformances.
The five elements of a process are:
- People – skilled individuals who understand the importance of process and change control
- Methods/Instructions – documented techniques used to define and perform a process
- Equipment – tools, fixtures, facilities required to make products that meet requirements
- Material – both product and process materials used to manufacture and test products
- Environment – environmental conditions required to properly manufacture and test products
Process Control Standards & Practices
A program as sophisticated as the Space Shuttle requires the integration of thousands of parts that must endure extreme
operating environments. Space hardware is produced by a broad supplier base using a wide variety of processes. Those
processes, if not controlled, can result in degradation of the end product and an associated increase in program risk.
Each manufacturer and supplier has unique systems for process control that guarantee the integrity of the hardware.
The Space Shuttle Process Control Management Plan defines the minimum requirements for process control related to flight hardware and critical ground support equipment for the Space Shuttle Program prime contractors.
The following are process control standards including examples of what some prime contractors have implemented to meet the standards. A summary of each practice including a point of contact is available by clicking on the link below.
STANDARDS & PRACTICES HANDBOOK
- Standard 1:
Detect and eliminate process variability and uncoordinated changes.
Examples:
- Standard 2:
Eliminate creep through process controls and audits.
Examples:
- Standard 3:
Understand and reduce process risks.
Examples:
- Standard 4:
Identify key design and manufacturing characteristics and share lessons learned relating to processes.
Examples:
- Standard 5:
Be personally accountable. Perform to written procedures.
Examples:
- Standard 6:
Promote process control awareness. Understand and report changes.
Examples:
- Standard 7:
Identify and evaluate changes to equipment and environment.
Examples:
- Standard 8:
Capture and maintain process knowledge and skills.
Examples:
- Statistical Process Control (SPC)
- Material fingerprinting
- Product/Process Integrity Audit (PPIA)
- NASA Engineering and Quality Audit (NEQA)
- Quality system audits
- Process Risk Matrix
- Characteristic Risk analysis
- Process Failure Modes Effects Analysis (PFMEA)
- Build-to-Packages
- Characteristic Accountability Worksheets
- Product fact sheets
- Process baseline
- Personal Warranty Program
- Space Flight Awareness Program (SFA)
- Motivational visits to suppliers/sub-tiers
- Symposiums
- Videos/Posters
- Product Protection Analysis (PPA)
- Configuration Management
- Engineering Source Approval (ESA)
- Manufacturing Material Control
- Mentoring
- Job shadowing
- Formal training and certification programs
- Skill assessments
Process Control Focus Group Contacts
Process Control Focus Group Chairperson
Mr. Armando Oliu
NASA-KSC
Kennedy Space Center, FL
(321)861-3042
Space Shuttle Program (SSP) Integration and Launch Support
Ms. Tammi Belt
United Space Alliance
Kennedy Space Center, FL
(321)867-8326
Ms. Lililee Johnson (281)212-6212
Reuseable Solid Rocket Motor
Mr. Glen Curtis
ATK Launch Systems
Brigham City, UT
(435)863-6954
Mr. Brad Sutherland (435)863-4360
Space Shuttle Main Engine
Mr. Rob Sobieski
Pratt & Whitney Rocketdyne
Canoga Park, CA
(818)586-2059
Mr. Ron Tyre (818)586-3013
Orbiter - Vehicle Integration
Mr. Steve Timmerman
Boeing Company
Houston, TX
(281)226-5934
Mr. Dwight Whitaker (281)282-6108
Extravehicular Mobility Unit
Mr. Michael Gemme
Hamilton Sundstrand Space Systems Intl.
Windsor Locks, CT
(860)654-5437
Mr. Lionel Ribeiro (860)654-3326
External Tank
Mr. Mark Rohlinger
Lockheed Martin Space Systems Michoud Operations
New Orleans, LA
(504) 257-2413
Mr. Michael Amman
(714) 822-2595
Mr. Tom Barrett
(310) 849-1401
Main Engine Turbo Pump
Mr. Fred Whitman
Pratt & Whitney Rocketdyne
West Palm Beach, FL
(561)796-9064
Mr. David Zapatka (561)796-5068
Johnson Space Center
Mr. Thomas Malatesta
NASA
(281)244-7843
Kennedy Space Center
Mr. Troy Heron
NASA
(321)861-5317
Ms. Terry Keeney (321)861-5382
Marshall Space Flight Center
Mr. Rick Williams
NASA
Canoga Park, CA
(818)586-9799
Stennis Space Center
Mr. Michael Smiles
NASA
(228)688-1642
Mr. Tim White (228)688-2390
Video Production
Mr. Todd Sims
Fusion Productions
Irving, TX
(972)869-1248
Mr. Bryon Wiebold (972)869-1248
