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
Distraction
The Space Shuttle Program community has been working diligently to determine the cause
of the hydrogen leak during tanking, which caused the launch of STS-127 to be delayed
twice. The team believes they have found the problem and is continuing with testing
and analysis to identify the root cause and solve the problem. Challenges such as this
are just one of many distractions that the workforce faces, which could potentially
lead to process escapes so it is imperative for everyone to remain diligent and focused
on their daily tasks.
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 suppliers working on the Space Shuttle Program 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.
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, Texas
(281)226-5934
Mr. Dwight Whitaker (281)282-6108
International Space Station
Mr. Jim Shearer
Boeing Company
Houston, Texas
(281)226-8982
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
Main Engine Turbo Pump
Mr. Fred Whitman
Pratt & Whitney Rocketdyne
West Palm Beach, Florida
(561)796-9064
Mr. David Zapatka (561)796-5068
Johnson Space Center
Mr. Thomas Malatesta
NASA
Huntington Beach, CA
(714)372-5234
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. Clayton Coblentz (972)869-1248
