Broad-Based TeamsCase Study #2 – Max Launch Abort System       Project Management Challenge 2009             Daytona Beach...
NESC Background  Engineering Excellence   2
NESC Overview•   In 2003, the NASA Engineering & Safety Center (NESC) was formed as a    response to a Columbia Accident I...
NESC Background    NESC emphasis is to create broad-based teams to enable networks    that discourage silos– Recruit team ...
MLAS Project Overview    Engineering Excellence   5
Original Action•   NASA’s former Associate Administrator for Exploration    Systems Mission Directorate, Scott Horowitz, a...
MLAS Task, Approach, and Success Criteria• Task:   –   Develop an alternate LAS design as risk mitigation for the       Or...
MLAS Conceptual Design             Replace                            Flight Test              With                       ...
MLAS Flight Test Vehicle Configuration•   Flight Test Vehicle (FTV) configuration has evolved as the design    has matured...
MLAS Flight Test Vehicle Configuration        Turnaround Drogues                                                          ...
MLAS Flight Test Vehicle Expanded View                                     Forward Fairing                                ...
Candidate Objective System – FTV Relationship                    Forward Fairing Shape                    & Motor Protuber...
MLAS Concept of Operations    Candidate Objective System   Stabilizing Grid   Fin Deployment                              ...
CM Parachute Demonstration Concept of Ops FTV reorientation via drogueparachutes in Forward Fairing                       ...
MLAS Benefits to Constellation Program•   Demonstration of pad abort with passive controls    –   First demonstration of a...
MLAS Benefits to Agency•   Demonstration of rapid large-scale    design and concurrent hardware    procurement•   Opportun...
MLAS Team Structure    Engineering Excellence   17
MLAS Team Structure                                                          MLAS                    Project Planning and ...
MLAS Team Composition•   Extended MLAS team comprised of 150 members, including    engineers, analysts, mentors, and resid...
Residents and Mentors    Residents                                 MentorsGary Dittemore (JSC)                      T.K. M...
MLAS Resident Engineer Opportunity•   Unique opportunity for    direct, on-going interaction    between MLAS residents,   ...
MLAS Project Management/Systems Engineering Approach        Engineering Excellence   22
MLAS Project Management Approach•   Focus on over-arching objectives     –   Meeting over-arching objectives defines MLAS ...
MLAS Rapid Prototype Philosophy•   Limited flight test objectives•   Conservative loads and dynamic    environments•   Pro...
MLAS Systems Engineering Process•   Mission Systems Engineer identified to lead design and trade study activities•   S&MA ...
MLAS Review Process•   MLAS tailored independent review    process    –   Not the formalized Preliminary/Critical        D...
Collaboration Approach     Engineering Excellence   27
Collaboration Approach•   Utilizing PDMLink in Windchill for configuration management•   Virtual team environment    –   U...
General Co-Location Goals•   Goals of co-locating:    –   Common understanding of project goals and success criteria    – ...
Co-Location Approach•   Co-location sessions are organized working sessions, not a formal    meeting/design review•   Begi...
Between Co-Locations•       Regular Team Tag-ups        –   Team leads or representatives            expected to participa...
Project StatusEngineering Excellence   32
Project Status Tooling plug foam machiningCrew Module simulator  Engineering Excellence       33
Project StatusForward Bay Cover outfitting with main parachutes (left)            and drogue parachutes (right)           ...
Project Status               Tooling plug foam machiningCM simulator fabrication complete and assembly,     Boost skirt an...
Project Status                Tooling plug foam machiningCM simulator fabrication complete and outfitting underway        ...
Project StatusCrew Module avionics buildup     Engineering Excellence    37
Project StatusCM avionics buildup complete and integrated test underway                   Composite fins                  ...
Upcoming Milestones•   Vehicle integration and test complete – early March 2009•   Independent Technical Review #3 – early...
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Schaible.dawn

  1. 1. Broad-Based TeamsCase Study #2 – Max Launch Abort System Project Management Challenge 2009 Daytona Beach, Florida February 24-25, 2009 Dawn M. Schaible NASA Engineering and Safety Center Engineering Excellence 1
  2. 2. NESC Background Engineering Excellence 2
  3. 3. NESC Overview• In 2003, the NASA Engineering & Safety Center (NESC) was formed as a response to a Columbia Accident Investigation Board observation• The NESC mission is to provide the Agency’s Programs and Projects with rigorous independent technical perspectives on their most critical technical issuesFive years later – The NESC remains independent:• Centrally managed and funded through the Office of Chief Engineer• Small staff of senior leaders and technical experts to lead broad-based engineering teams in “tiger team” fashion• Unaffiliated with and unbiased by any specific NASA Program or Center• Has an independent engineering chain of command to assure an avenue for consideration of all points of view• Facilitating hands-on design and development experience Engineering Excellence 3
  4. 4. NESC Background NESC emphasis is to create broad-based teams to enable networks that discourage silos– Recruit team membership – Facilitate inter-Center from a broad community collaboration– Increase inter-Center – Encourage inter-Center knowledge and information relationships and flow communities of practice Engineering Excellence 4
  5. 5. MLAS Project Overview Engineering Excellence 5
  6. 6. Original Action• NASA’s former Associate Administrator for Exploration Systems Mission Directorate, Scott Horowitz, asked the NESC to develop an alternate design as risk mitigation for the Orion Launch Abort System (LAS) concept. The alternate concept will be demonstrated by a pad abort test – The highest risk (at that time) for the Orion LAS design was the Attitude Control Motor (ACM) – Team is focused on LAS concepts that eliminate or mitigate the need for complex controls• “Max” LAS (MLAS) named in honor of Maxime Faget, the original designer of the Project Mercury capsule and holder of the patent for the “Aerial Capsule Emergency Separation Device” (escape tower) Engineering Excellence 6
  7. 7. MLAS Task, Approach, and Success Criteria• Task: – Develop an alternate LAS design as risk mitigation for the Orion LAS. Demonstrate the alternate concept with a pad abort flight test• Approach: – Strive to identify the simplest design that will satisfy launch abort requirements while maximizing nominal ascent performance – Implement flight test by using off-the-shelf parts wherever possible to minimize cost and shorten schedule• Success Criteria: – Obtain sufficient flight test data to assess performance, validate models/tools, and support an MLAS Objective System design Engineering Excellence 7
  8. 8. MLAS Conceptual Design Replace Flight Test With Vehicle Candidate MLAS MLAS Flight Test Objective System Vehicle Design CurrentOrion ALAS Engineering Excellence 8
  9. 9. MLAS Flight Test Vehicle Configuration• Flight Test Vehicle (FTV) configuration has evolved as the design has matured, driven by rapid prototype/off-the-shelf hardware approach• Current MLAS configuration has four center-clustered MK-70 motors aft-mounted in a separable boost skirt – Early plan to fly forward-mounted motors would have required development of a manifold to accommodate thrust dispersions – Manifold development posed a high project risk – Aft-mounted MK-70 motors addressed the thrust dispersion problem without the manifold• Objective system flight stability hardware simulated with planar fins attached to a separable coast skirt• FTV flight will demonstrate stable coast configuration, drogue- assisted turnaround, Crew Module (CM)-fairing separation, and alternate CM parachute recovery Engineering Excellence 9
  10. 10. MLAS Flight Test Vehicle Configuration Turnaround Drogues Modified Sears-Haack Fairing Motor SimulatorsSeparation Joints Coast Skirt Boost Skirt Drag Plates Internally-Mounted Motors Engineering Excellence 10
  11. 11. MLAS Flight Test Vehicle Expanded View Forward Fairing CM Simulator Coast Skirt Motor Cage Boost SkirtFrangible Joints Engineering Excellence 11
  12. 12. Candidate Objective System – FTV Relationship Forward Fairing Shape & Motor Protuberances Flight Test Vehicle Conventional Fins Sized to Match Grid Fin Stability Increment to Achieve Early Passive Flight Demonstration Boost Motors Moved Aft to Eliminate Motor Manifold Booster Risk to Flight Test Engineering Excellence 12
  13. 13. MLAS Concept of Operations Candidate Objective System Stabilizing Grid Fin Deployment Separate Fins Design Trade Space Flight Test Data Flight Test Vehicle Boost Skirt Coast Skirt Separation Separation MLAS Flight Test Objectives Separate Stabilization Devices Reorientation CM Delivery to ReleasePad Abort Initiation Powered Ascent Stable Coast And Begin Reorientation And Stabilization Point Conditions Engineering Excellence 13
  14. 14. CM Parachute Demonstration Concept of Ops FTV reorientation via drogueparachutes in Forward Fairing CM separation from MLAS Forward Fairing CM drogue parachute deployment CM Forward Bay Cover release to extract main parachutes CM main parachute deployment Engineering Excellence 14
  15. 15. MLAS Benefits to Constellation Program• Demonstration of pad abort with passive controls – First demonstration of a passively-stabilized LAS on a vehicle in this size and weight class• Collection of full-scale aeroacoustic environment data – First test to acquire full-scale aeroacoustic environment data on a faired capsule concept• Demonstration of CM fairing/separation – First test to demonstrate full scale fairing/CM separation and measure associated aerodynamic and orientation data• Demonstration of CM main parachute deployment using Shuttle Solid Rocket Booster recovery-based system Engineering Excellence 15
  16. 16. MLAS Benefits to Agency• Demonstration of rapid large-scale design and concurrent hardware procurement• Opportunity to anchor aerodynamic analysis to flight data for a design strongly influenced by analytical models and engineering Transonic Wind Tunnel Testing at Calspan assumptions• Accumulation of flight data for a unique length-to-diameter vehicle• Unique opportunity for hands-on training afforded the next generation of Agency engineers Resident Engineer Omar Torres testing separation dynamics at University of Washington Engineering Excellence 16
  17. 17. MLAS Team Structure Engineering Excellence 17
  18. 18. MLAS Team Structure MLAS Project Planning and Project Management Mentors Control Project Manager – R Roe and L Leybold Deputy PM – T Wilson Resident Engineers Chief Engineer – M Gilbert SE&I S&MA Aerodynamics Propulsion D Schaible G. Kelm D Schuster C Schafer J Berry - MSE Structures Avionics Software Landingand Mechanisms and Instrumentation M Aguilar D YuchnoviczM Kirsch / T Palm M Davis SpaceFibre CM Parachutes G. Rakow C Shreves Ground OpsFlight Mechanics Loads and Dynamics B Underwood / S Minute N Dennehy C Larsen / K Elliott B Hall – Vehicle Mgr NESC Technology Demonstrators Engineering Excellence 18
  19. 19. MLAS Team Composition• Extended MLAS team comprised of 150 members, including engineers, analysts, mentors, and resident engineers from across the Agency and industry Engineering Excellence 19
  20. 20. Residents and Mentors Residents MentorsGary Dittemore (JSC) T.K. MattinglyGeminesse Dorsey (JSC) Jerry McCulloughJoe Grady (GRC) Tom ModlinSamantha Manning (KSC) Dave ShemwellSamuel Miller (LaRC) Milt SilveiraTheodore Muench (GSFC) Bob WestTerrian Nowden (GRC)Sarah Quach (KSC)Jerry Sterling (GSFC)Omar Torres (LaRC) Engineering Excellence 20
  21. 21. MLAS Resident Engineer Opportunity• Unique opportunity for direct, on-going interaction between MLAS residents, Resident engineers NASA Technical Fellows, assisting in composite fin and Apollo-era veterans testing• Limited scope and short duration of the MLAS project provides rare systems engineering experience• “Off-line” nature of the project provides an opportunity to try-and-fail Resident engineers Sam Miller and Gary Dittemore performing camera vibration testing Engineering Excellence 21
  22. 22. MLAS Project Management/Systems Engineering Approach Engineering Excellence 22
  23. 23. MLAS Project Management Approach• Focus on over-arching objectives – Meeting over-arching objectives defines MLAS Project success – Manage critical path – Additional requirements to buy themselves in• MLAS Team requirements and design baseline are controlled by team’s MLAS Configuration Control Board (CCB) • Project Manager – Chair • Deputy Project Manager • Chief Engineer • Systems Engineering and Integration (SE&I) Lead • Safety and Mission Assurance (S&MA) Lead • Subteam Leads• Periodic co-locations and virtual integrated design sessions• Providing design, development, and test training opportunity through Resident Engineer Program Engineering Excellence 23
  24. 24. MLAS Rapid Prototype Philosophy• Limited flight test objectives• Conservative loads and dynamic environments• Proto-flight structural margins• Low cost, minimum lead time materials and processes - Not mass driven• Statically stable during boost and coast• Ballast vehicle and adjust launch stool angle to meet trajectory constraints• Design schedule prioritized by production and assembly sequence• Maximum use of proven, off-the-shelf hardware Northrop Grumman Ship Systems, Gulfport Engineering Excellence 24
  25. 25. MLAS Systems Engineering Process• Mission Systems Engineer identified to lead design and trade study activities• S&MA representatives included as part of core SE&I team• FTV configuration designed using rapid prototype philosophy• Utilize Products Needs List to track data deliverables between teams• Defining documents: – Requirements, Interface Control Documents, Design Data Book, Flight Test Plan, Ground Operations Plan – Minimized formal documentation and eliminated boilerplate information as much as practical• Streamlined configuration control process – Utilize standing meeting for MLAS CCB for design changes and reviews• Tailored independent review process – Goal is a thorough, independent review with a variety of perspectives, experiences, and processes considered• Safety process employs hazard analysis and risk management processes without detailed failure mode and effects analysis Engineering Excellence 25
  26. 26. MLAS Review Process• MLAS tailored independent review process – Not the formalized Preliminary/Critical Design Review process – Conducting a series of Independent Technical Reviews (ITR) • ITR1 conducted in November 2007 - Gain confidence to procure long-lead materials and tooling • ITR2 conducted in April 2008 - Conducted sub team peer reviews in preparation - Gain confidence to fabricate flight hardware and ground support equipment • ITR3 planned for March 2009 - Gain confidence to conduct the pad ITR 2 at LaRC in April 2008 abort flight test Engineering Excellence 26
  27. 27. Collaboration Approach Engineering Excellence 27
  28. 28. Collaboration Approach• Utilizing PDMLink in Windchill for configuration management• Virtual team environment – Using WebEx and Windchill – Monthly co-location of team – Establish multi-disciplinary teams to address integrated issues – Virtual integrated design sessions – Utilize instant messaging and desktop sharing Engineering Excellence 28
  29. 29. General Co-Location Goals• Goals of co-locating: – Common understanding of project goals and success criteria – Facilitate rapid decision making – Reinforce project schedule, critical path, and upcoming milestones – Align expectations for upcoming deliverables – Build teamwork Team co-locations at LaRC Engineering Excellence 29
  30. 30. Co-Location Approach• Co-location sessions are organized working sessions, not a formal meeting/design review• Begin each co-location with a kick-off briefing – Reinforce project success criteria and exit criteria• Begin each day with a 30 minute kick-off meeting at 8:30 – Meeting has a definite end – Assign actions for small groups to work, with achievable deliverables – Identify hot topics for the day• Utilize white board to schedule “hot topics” – a list of meetings, times, participants, and objectives• Meetings, priorities, and hot topics facilitated by SE&I• All team members, including mentor and resident teams, expected to attend each co-location if possible Engineering Excellence 30
  31. 31. Between Co-Locations• Regular Team Tag-ups – Team leads or representatives expected to participate – Communicate major results, issues, and product needs – Frequency of meetings adjusted during each stage of project – Splinter meetings scheduled as needed – Agendas for tag-up meetings are Team Tag-up at Wallops Flight Facility projected a week ahead of time and distributed daily – Use forum for MLAS CCBs as needed • Conduct periodic schedule reviews and action status reviews • Communication, communication, communication Engineering Excellence 31
  32. 32. Project StatusEngineering Excellence 32
  33. 33. Project Status Tooling plug foam machiningCrew Module simulator Engineering Excellence 33
  34. 34. Project StatusForward Bay Cover outfitting with main parachutes (left) and drogue parachutes (right) Engineering Excellence 34
  35. 35. Project Status Tooling plug foam machiningCM simulator fabrication complete and assembly, Boost skirt and coast skirt outfitting underway Forward fairing quarter panels Engineering Excellence 35
  36. 36. Project Status Tooling plug foam machiningCM simulator fabrication complete and outfitting underway Forward fairing quarter panel Engineering Excellence 36
  37. 37. Project StatusCrew Module avionics buildup Engineering Excellence 37
  38. 38. Project StatusCM avionics buildup complete and integrated test underway Composite fins Engineering Excellence 38
  39. 39. Upcoming Milestones• Vehicle integration and test complete – early March 2009• Independent Technical Review #3 – early March 2009• Vehicle transfer to pad complete – Mid-March 2009• Target flight test date – March 27, 2009 Northrop Grumman Ship Systems, Gulfport Engineering Excellence 39

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