Tutorial: Detecting, Retaining and Preventing Failures


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Tutorial: Detecting, Retaining and Preventing Failures

  1. 1. 25th Aerospace Testing Seminar Tutorials The Aerospace Testing Seminar starts with a full day of tutorial sessions on Monday, October 12. Full Day Sessions (8 a.m. – 4:30 p.m.) Test Like You Fly, Parts I and II Morning Session Only, Part I (8 a.m. – 11:30 a.m.) Afternoon Session Only, Part II (1 p.m. – 4:30 p.m.) The Keys to Space Vehicle Integration and Testing, Parts I and II Morning Session Only, Part I (8 a.m. – 11:30 a.m.) Afternoon Session Only, Part II (1 p.m. – 4:30 p.m.) Software Testing, Parts I and II Morning Session Only, Part I (8 a.m. – 11:30 a.m.) Afternoon Session Only, Part II (1 p.m. – 4:30 p.m.) Morning Only Sessions (8 a.m. – 11:30 a.m.) Applied High Frequency Structural Dynamics, Shock and Acoustics Detecting, Retaining and Preventing Failures Introduction to MIL-STD-1540E, Test Requirements for Launch, Upper-stage and Space Vehicles Afternoon Only Sessions (1 p.m. – 4:30 p.m.) EMC/EMI Testing Static and Dynamic Testing of Space System Structures Thermal Testing and Verification
  2. 2. Full Day Sessions (8 a.m. – 4:30 p.m.) Test Like You Fly (TLYF), Parts I and II Instructors: Julia White, The Aerospace Corporation, Lindsay Tilney, The Aerospace Corporation, and Frank Knight, The Aerospace Corporation Description: “Test Like You Fly” is a term that has progressed from being an undefined notion to an assessment and implementation process. This tutorial will cover the following topics: the on- orbit failures that showed a need for more formality in applying TLYF principles; the philosophical underpinning for TLYF; the TLYF assessment process; what you need to know about the mission to be able to test “like you fly;” how to architect and design LYF tests; how to implement TLYF at any program development phase; and how to determine and manage the risk of what cannot or will not be tested in a “like you fly” manner. Attendees will be invited to join an ongoing TLYF government/industry community of practice to participate in the continuing development of this technique for space systems. Instructor Biographies: Julia “Julie” White is currently a Senior Engineering Specialist in the Cross Program Systems Engineering Office for the Aerospace Corporation. Her work is now focused on establishing an industry standard process for "test like you fly" assessments and implementation for use as a Mission Assurance / Mission Success technique. She has been with The Aerospace Corporation for 34 years, 18 of which were spent in the Space Test Program Office helping develop six R&D spacecraft. She holds a Dual Bachelors Degree in Physics and Astronomy from the University of Maryland and a Masters in Astronomy from the University of Massachusetts. Lindsay Tilney is currently a Senior Engineering Specialist in the Software Assurance Department for The Aerospace Corporation. She has more than 24 years of experience in the aerospace industry, including satellite software design and analysis, flight planning for payloads that fly on the Space Shuttle, ground system design, satellite on-orbit testing, and system software modeling and simulation. She holds a Bachelor of Science degree in Mathematics and Computer Science from the University of California at Los Angeles. Tilney is a co-author for the recently revised Test Like You Fly Guidelines chapter for the 2nd edition of the Space Vehicle Test and Evaluation Handbook, and a co-author of the soon to be released Test Like You Fly Lifecycle Guidelines. Frank Knight is Systems Director of the Systems Engineering and Software Directorate for The Aerospace Corporation. He and his directorate are responsible for establishing systems engineering fundamentals to assure acquisition and mission success. This involves a wide range of engineering disciplines, including systems engineering planning and processes, mission assurance, specifications and standards, parts, materials and processes, systems engineering policy, software acquisition, environmental engineering, and space industrial base concerns. His group is also the principal Aerospace support to the SMC Center Test Authority (CTA) in the office of the SMC Chief Engineer. One facet of their work is implementing "Test Like You Fly (TLYF)" for all SMC programs. He was also the co-lead for the TLYF Topic Team at the 2009 Mission Assurance Improvement Workshop. Knight has been with The Aerospace Corporation for 30 years, in a variety of assignments in the Engineering and Technology Group and in program and staff offices. He has Bachelor of Science and Master of Engineering degrees in
  3. 3. Mechanical Engineering from the University of South Carolina and an Engineer in Mechanical Engineering degree from the University of Southern California. The Keys to Space Vehicle Integration and Testing, Parts I and II Instructors: Bruce Arnheim, The Aerospace Corporation, and Charlotte Belsick, Lockheed Martin Space Systems Company Description: This course presents the entire space vehicle integration and test (I&T) process. The course covers planning and verification through I&T design and execution. Also covered are key aspects for the I&T phases, including lessons learned, benchmarking, cost and schedule considerations, and traps to avoid. This course is designed to provide an overview of space vehicle integration and test for both engineers and managers. Instructor Biographies: Bruce Arnheim is Director of Mission Assurance and System Test for the Aerospace Corporation’s Space Based Surveillance Division. Arnheim has more than 29 years of experience in aerospace, ranging from RF design, advanced systems design, new business development, systems engineering, and systems test. Currently, he is responsible for the program execution of SBIRS HEO and system test activities on the SBIRS High program. He holds a dual Bachelor’s degree in Engineering from Harvey Mudd College and Economics from Claremont McKenna College, and an MBA from Pepperdine University. He has been a member of the Aerospace Testing Seminar’s advisory board for 16 years. Among his awards, Arnheim is the recipient of two NRO Director’s awards, the Otto Hamberg Best Paper award, and the 2006 SBIRS Wing Aerospace Employee of the year. In 2007, he was given the Trustee’s Distinguished Achievement Award “for enhanced mission assurance leading to recovery and delivery of the SBIRS HEO payload.” Charlotte Belsick is the International Space Station Chief Systems Engineer (CSE) for Lockheed Martin Space Systems Company. For more than 25 years, she has been involved in the aerospace industry, including manned flight, missiles, and space systems. She started her career in the aircraft test labs, moving through different experiences with increasing responsibility, and is now the CSE, responsible for systems Engineering, Integration, and Test. Belsick’s previous assignments included the SBIRS Mission Success Manager where her focus included test, failure detection, and troubleshooting for a system of system constellation and the Civil Space Chief Engineer where she was responsible for the technical oversight and engineering of the NASA remote sensing and space sciences programs including the system testing and launch of five different satellites. In addition, she has served on numerous readiness review panels, investigation teams, and red teams. She is a Fellow of the American Society of Testing and Materials. She holds a Bachelor of Science in ME from San Diego State University and is currently working on her Master of Science in Aerospace Engineering-Systems Engineering from CalPoly-San Luis Obispo. Software Testing, Parts I and II Instructors: Douglas J. Buettner, The Aerospace Corporation, and Suellen Eslinger, The Aerospace Corporation Description: This course provides the entire software testing process for software-intensive space systems in an interactive learning environment. The student will be involved in learning aspects of test
  4. 4. problem solving techniques, anomaly handling, troubleshooting, the anatomy of a good bug report and what is it that the software engineer does to resolve that bug report in the first place. Instructor Biographies: Doug Buettner is the Systems Director for Flight Software and Ground Test Equipment Software in the Space Based Surveillance Division at The Aerospace Corporation. Buettner has more than 15 years of experience in the software industry, holding quality assurance management and software test lead positions on software-intensive systems. In addition, he has been a repeat speaker at software testing conferences on advanced methods for testing algorithmically complex software. He has a Bachelor of Science and a Masters Degree in Physics from Oregon State University, where he did research that ultimately led to the Jet Propulsion Laboratory’s STARDUST mission. He is an Aerospace Corporation Fellow and a Ph.D. Candidate in Astronautical Engineering with a focus in Computer Science at the University of Southern California. Suellen Eslinger is a Distinguished Engineer in the Software Engineering Subdivision at The Aerospace Corp. Eslinger has over 40 years of experience in software engineering and acquisition of software- intensive systems. Prior to her 23 years at Aerospace, she worked at Computer Sciences Corp. and General Research Corp., where she developed software and managed software development projects for DoD and NASA. She has a Bachelor of Arts and a Master of Science in Mathematics, from Goucher College and University of Arizona, respectively. Morning Sessions (8 a.m. – 11:30 a.m.) Applied High Frequency Structural Dynamics, Shock & Acoustics Instructor: Richard Foss, Lockheed Martin Space Systems Company Description: The tutorial covers basics associated with the high frequency structural excitation sources of shock and acoustics. Characterization of energy sources associated with these phenomena, the nuances of structural coupling, and how the sources and responses are measured and analyzed will be a central theme of this discourse. Instructor Biography: Dick Foss began his engineering career at Lockheed Martin Astronautics in Denver in 1983 where he has specialized in vibration, acoustics, mechanical design and test. His experience in the space industry spans several tiger-team recovery efforts, POGO assessments, Solid Rocket Motor integration, Liquid Engine health assessments and rotor-dynamics to science acquisition mechanism design for space discovery missions, and sample return capsule development. He currently supports the Test Department at Lockheed Martin Space Systems Company. Detecting, Retaining and Preventing Failures Instructor: Barbara (“Barb”) Sande, Lockheed Martin Space Systems Company Description: This tutorial will explore successful and proven strategies to detect failures when they occur, retain failure characteristics to allow for comprehensive troubleshooting and analysis to root
  5. 5. cause, and prevent failures from occurring by improving designs and processes. The tutorial will use examples, exercises and extensive graphics to enhance the learning experience for the student. Instructor Biography: Since 2005, Barb Sande has been a Mission Success Integration senior staff engineer; previously, she spent 25 years in technical and lead positions on the Titan launch vehicle program. She performs special technical studies, manages a legacy learning project to document historical successes and failures, and advises programs on improved operational spacecraft anomaly trending processes. Sande is a recognized expert in data analysis, lean/six sigma tools, problem resolution, risk management, and technical writing and presenting. She is a certified Lean/Six Sigma Black Belt and co- chaired the Titan program Black Belt Board, which approved certification of 202 Green Belts and 11 Black Belts. She currently serves as the Lean/Six Sigma Point of Contact for the SSC Mission Success and Internal Audit organizations. She has recently facilitated improvement events for human space flight and classified spacecraft programs. Sande has presented papers and tutorials at the Aerospace Testing Seminar, AIAA Space, Space Launch Integration and Joint Propulsion conferences, Lean Aerospace Initiative Plenary, University of Colorado Aerospace Senior Design Seminars, Mission Critical Enterprise Symposium, American Society for Quality and International Council on Systems Engineering. Sande co- developed a risk/opportunity management process and tool that was submitted for patent consideration. She also contributed to the Titan History Project, authoring the official final launch history record and story of Titan Mission Success. She is a representative to the LMSSC Diversity Council, an active Council Member of AIAA Rocky Mountain section and has been a JPL Solar System Ambassador (Community Outreach and Education program) since 2005. She has received numerous LMSSC individual and team awards, a Diversity Champions Award and received the Otto Hamberg Award in 2000 for best paper at the 19th Aerospace Testing Seminar. Education B.S., Electrical Engineering, University of Colorado at Boulder, 1977 MBA, Information Systems, University of Colorado at Denver, 1983 Apollo Root Cause Analysis, Technical Kickoff Facilitation Certified Lean/Six Sigma Black Belt and Lean/Six Sigma Green Belt Registered Professional Engineer, State of Colorado Introduction to MIL-STD-1540E, Test Requirements for Launch, Upper- stage and Space Vehicles Instructor: James Snyder, The Aerospace Corporation Description: This tutorial includes an overview of why we test and the criteria leading to the specified requirements that provide a foundation for building a thorough test program. It brings out the importance of a rigorous and perceptive test program, and how a space system’s reliability is enhanced as a result. Test philosophy, criteria, and approaches will be presented and reinforced using historical data and lessons learned. It will also provide a status of the B revision to MIL-HDBK-340 currently in work. Instructor Biography: Jim Snyder is a Senior Engineering Specialist in The Aerospace Corporation’s Environments, Test and Assessment Department. He joined Douglas Aircraft Co. in Long Beach, Calif., after receiving his BSME from Cal Poly Pomona in 1967. He started his career as a Structural Test Engineer, conducting tests on nearly every jet-powered aircraft built at the Long Beach plant, including the
  6. 6. A3, A4, YC-15, DC-8, DC-9, MD-80/90, DC-10, MD-11 and T45. Snyder became a manager in 1980 and led the Test Engineering Team for several years. He transferred to the Space and Defense Component of McDonnell Douglas (now Boeing) at Huntington Beach, Calif., in 1991, assuming the responsibilities of Senior Manager of the Engineering Labs, where he led a team of Test Engineers and Technicians. This team successfully conducted testing for numerous test programs including the Delta III/IV, International Space Station, X-37 ALTV, and Delta Clipper. In April of 2004, Snyder retired from Boeing and assumed his current position at The Aerospace Corporation, where he has been involved in various projects, including updating MIL-STD-1540, authoring sections of two new Aerospace handbooks, and consulting on several military satellite test programs. Afternoon Sessions (1 p.m. – 4:30 p.m.) EMC/EMI Testing Instructor: Mark Simpson, The Aerospace Corporation Description: You will learn about the core issues involved in developing a MIL-STD-1540E (draft) compliant test program. The emphasis will be on learning concepts and principles. All experience levels are welcome. All background material will be provided. You will learn how to approach using MIL-STD- 1541A with either MIL-STD-461C or MIL-STD-461E or when using MIL-STD-1541B (draft) with MIL-STD- 461E. You will learn about critical facility choices, such as, when to use an anechoic chamber over an EMI shield room and the different types of anechoic chambers. You will learn how changes to the flight configurations, (i.e., load simulator, presence of solar arrays, installation of multilayer thermal blankets, and antenna deployments) can impact your test results. You will learn about modes of operations and the difference between test modes and flight modes, and if you really need to test all modes of operations, and is the worst case really worst case. You will learn about success/fail criteria and why measuring performance directly is required. There will be time for questions and answers at the end of the program. Instructor Biography: Mark Simpson has 25 years of industry experience. He has spent the last 18 years at The Aerospace Corporation. He is currently the Senior Project Leader of the Electromagnetic Effects Section and is responsible for coordinating the EMC support to about a dozen Air Force space program offices. Simpson wrote the update for the EMC portions of MIL-STD-1540 and oversaw the rewrite of MIL-STD-1541. He has received numerous letters of commendation for his work and has published four papers. Static and Dynamic Testing of Space System Structures Instructor: Paul A. Larkin, Larkin Enterprises Inc. Description: This course will present material and concepts necessary for the successful development and verification of spacecraft structural systems. Material covered will include requirements flow down, structural environments, test definitions, test flow, verification and test for: static, modal, sine, random, force limited vibration, shock and workmanship.
  7. 7. Instructor Biography: Paul Larkin has more than 30 years of experience working with aerospace structures. He has contributed to the design, analysis, fabrication and test of major NASA, DOD, DOE and commercial space programs. He was employed as a structural dynamics engineer and later as lead mechanical engineer by Fairchild Space Systems Division from 1979 until 1993. From 1993 until 1995 he worked for CTA Launch Services and later CTA Space Systems in McLean, Va. From 1995 until 1998, Larkin was president of his own consulting company, providing structural and mechanical design analysis and test services. After that, he was employed by Orbital Sciences Corporation’s Space Systems Group where he served as a member of the Chief Engineer’s Staff. From 2001 to 2008, Larkin was a principle member of the technical staff at Sandia National Laboratories where he participated in the dynamic analysis and test of aerospace and weapons systems. Larkin is experienced in the definition of satellite mechanical requirements, environments, layout, configuration, design, analysis, mechanisms, integration, environmental test (definition, planning and execution) and launch support activities. His Sandia National Laboratories experience has added experience associated with test Project Management, Environmental Test Facility Owner and Test Director. In addition, Larkin has experience with the specification and purchase of instrumentation, control and test equipment and in performing analog and digital signal processing, data reduction and interpretation of most types of dynamic test data. He holds an Master of Science degree in Civil engineering from Columbia University in New York City and is currently employed as an independent consultant providing engineering services in the areas of structural/mechanical analysis, design and test, vibrations, acoustics, program guidance on requirements definition, environments, verification and validation, design and test standards, systems engineering, technical reviews, and program planning and scheduling. Thermal Testing and Verification Instructor: John Welch, The Aerospace Corporation Description: This course provides the background and specific information toward understanding the purposes and critical parameters in thermal tests. The scope covers thermal cycling, thermal vacuum, thermal balance, burn-in, model correlation, and test facilities. Instructor Biography: John Welch is a Senior Engineering Specialist in the Spacecraft Thermal Department at The Aerospace Corporation. His expertise includes thermal testing, interface thermal conductance, and unit thermal design techniques. He is the author of the Thermal Testing chapter in the “Satellite Thermal Control Handbook” and the “Spacecraft Thermal Control Handbook.” He has authored papers on thermal testing and taught courses on the subject through The Aerospace Institute, AIAA and the University of California, Los Angeles. Welch holds Bachelor of Science and Master of Science degrees in Mechanical Engineering from the University of Washington.