Ares I Instrument Unit Status and Progress

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Presentation by Dwight Potter (Boeing Exploration Launch Systems Deputy, IUA Program Manager, Boeing) at the Von Braun Memorial Symposium in Huntsville, Alabama, 21 October 2008.

<a href="http://astronautical.org/vonbraun/vonbraun-2008/session1">http://astronautical.org/vonbraun/vonbraun-2008/session1</a>

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  • 09/07 Welcome, and thank you for taking this time with me. I would like to share with you some of the exciting things being done by your space program.
  • Ares I Instrument Unit Status and Progress

    1. 1. Dwight Potter Boeing Exploration Launch Systems Deputy, IUA Program Manager
    2. 2. Boeing Producibility Team <ul><li>Boeing has been selected as the USPC and IUAC </li></ul><ul><ul><li>Producibility and Design Support </li></ul></ul><ul><ul><li>Manufacturing Operations </li></ul></ul><ul><ul><li>Sustaining Engineering </li></ul></ul><ul><li>USP Program Manager – Jim Chilton </li></ul><ul><li>IUA Program Manager – Dwight Potter </li></ul><ul><li>Team is engaged with NASA Design Team (NDT) </li></ul><ul><ul><li>Manufacturing Value Stream Mapping </li></ul></ul><ul><ul><li>Producibility Summit </li></ul></ul><ul><ul><li>Tooling Design Support </li></ul></ul><ul><ul><li>Schedule Development </li></ul></ul><ul><ul><li>Component Cost Updates </li></ul></ul><ul><ul><li>Test Article Planning Support </li></ul></ul><ul><ul><li>Special Studies </li></ul></ul>
    3. 3. <ul><li>Our Objective – Safe and Affordable Ares I Upper Stage </li></ul><ul><li>We used the Value Stream approach to develop “how” </li></ul><ul><li>Imperatives guide our approach </li></ul><ul><li>Determined needed resources using proven methods </li></ul><ul><li>Value added from Delta IV and other processes to NDTs existing approach </li></ul>Production – Strategic Overview Objective Value Stream Mapping Four Manufacturing Imperatives: Safety, Incremental Transition, Innovation, R&O Management Resource Needs: Facilities Staffing Supply & Tooling Chain Manufacturing Processes: Friction Stir Welding, Ultrasonic Inspection, Robotic SOFI…
    4. 4. Manufacturing Imperatives <ul><li>Workforce, hardware and mission safety </li></ul><ul><li>Achieve design phase objectives </li></ul><ul><ul><li>Flow time </li></ul></ul><ul><ul><li>Team size </li></ul></ul><ul><ul><li>Surge capability </li></ul></ul><ul><li>Structured production readiness process </li></ul><ul><li>MAF capability re-use </li></ul>
    5. 5. The Production Strategy Requires Designing the Production Flow Along with the Product The Value Stream Approach A Program Leadership Tool Step #1 Start with the Answer: Program Sets Targets <ul><li>Objectives </li></ul><ul><ul><li>Customer expectations </li></ul></ul><ul><ul><li>Quality improvement </li></ul></ul><ul><ul><li>Cycle time reduction </li></ul></ul><ul><ul><li>On-time delivery </li></ul></ul><ul><ul><li>Improve cost </li></ul></ul>Step #2 <ul><li>Value Stream Mapping </li></ul><ul><ul><li>Engage teams in the “How” </li></ul></ul><ul><ul><li>Identify waste in the process (starbursts) </li></ul></ul><ul><ul><li>Seek new value </li></ul></ul><ul><li>A Baseline </li></ul>Step #3 <ul><li>Value Stream Analysis </li></ul><ul><ul><li>Design to achieve program vision </li></ul></ul><ul><ul><li>Integrate Lean Best Practices to reduce waste </li></ul></ul><ul><ul><li>Integrate Program Management Best Practices for Execution </li></ul></ul>Step #4 <ul><li>Action Plan </li></ul><ul><ul><li>Program commitment/ownership </li></ul></ul><ul><ul><li>Team improvement targets </li></ul></ul><ul><ul><li>Team Lean plans </li></ul></ul><ul><ul><li>Seize Opportunities </li></ul></ul><ul><ul><li>Visible to all </li></ul></ul>
    6. 6. Lean Approach is Driving Upper Stage and Instrument Unit Integration <ul><li>Updated and mature production for a right sized production system, timeline and simulation </li></ul><ul><ul><li>Improve production layouts at MAF. </li></ul></ul><ul><ul><li>Add definition to flows </li></ul></ul><ul><ul><li>Reduce flow times for materials, people, hardware, information, tooling </li></ul></ul><ul><li>IUA manufacturing & assembly flow integrated to improve and mature the overall flow. </li></ul><ul><ul><li>Define details on IU process flow (All integration and testing) </li></ul></ul><ul><ul><li>Seek opportunities to reduce IU process flow time. </li></ul></ul><ul><ul><li>Identify missing support hardware/software </li></ul></ul><ul><ul><li>Include any process flow to turn over the IU structure (DD250 baseline) </li></ul></ul><ul><ul><li>Any flow to turn over the integrated assembly (DD250 baseline) back to the US contract </li></ul></ul>IU Box Installation Simulation IU Assembly onto Upper Stage
    7. 7. Engaging the Supply Chain <ul><li>Source Control Item and Component End Item Procurements Underway </li></ul><ul><ul><li>Upper Stage Production </li></ul></ul><ul><ul><ul><li>Ullage Settling Motors: Proposals received and in evaluation </li></ul></ul></ul><ul><ul><ul><li>Pyros: Proposals received and in evaluation </li></ul></ul></ul><ul><ul><li>Instrument Unit Avionics </li></ul></ul><ul><ul><ul><li>Flight Computer/Command Telemetry Computer: Proposals received and in evaluation </li></ul></ul></ul><ul><ul><ul><li>Battery: RFP released to industry this month </li></ul></ul></ul><ul><ul><ul><li>Combined Control System Electronics: RFP released to industry </li></ul></ul></ul><ul><ul><li>All remaining procurements to be completed in 2009 </li></ul></ul><ul><li>Exceeding Supplier Diversity Goals & Reaching Out </li></ul><ul><li>Mentoring and Developing Small Businesses </li></ul>
    8. 8. Summary <ul><li>Supporting NASA in the development of a safe & affordable Upper Stage </li></ul><ul><li>Made extensive producibility inputs into the design process </li></ul><ul><li>Optimize manufacturing costs through lean approaches </li></ul><ul><li>Have a plan to engage and integrate the Supply Chain into the program </li></ul>

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