Introduction-for_management_program(part_1)

Introduction for Management Program
(Part 1)
Textbook for Space Development
Copyright © 2015 Japan Aerospace Exploration Agency All Rights Reserved. 1

2
Title Introduction for Management Program (Part 1)
Overview This text “Introduction for Management Program (Part 1)” explains
the procedures and management techniques to ensure the quality
and reliability in the development of space products. The
management techniques to treat with the safety control,
configuration control, risk control and EEE parts control are
described in the subsequent text “Introduction for Management
Program (Part 2)”.
Purpose of
This Unit
Improve the management ability in the development of
spacecrafts and the engineering design ability of satellite system
and a variety of subsystems.
This Unit for Administrative Officer, Engineer (Introduction), Engineer
(Beginner), Engineer (Intermediate)
Requirement
for Taking This
Unit
Project Management Process, Introduction to Satellite
Overview (1/2)
Copyright © 2015 Japan Aerospace Exploration Agency All Rights Reserved.

3
When You
Master This
Unit…
 You can learn five major management program in spacecraft
development.
 You can learn the meaning of reliability, the calculation
procedure of reliability, major design techniques in reliability
engineering such as FMEA, FTA and etc.
 You can learn the estimation method of reliability.
 You can learn the fundamentals such as management items
and dispositions of non-conforming articles in Quality
Assurance Program.
Overview (2/2)

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• 1. Project Management Process
overview of project management process
• 2. Reliability Program
–meaning of reliability, failure patterns, failure rate, calculation
method of reliability.
–reliability design, reliability prediction, redundant design,
reliability review.
• 3. Quality Assurance Program
– planning of Quality Assurance Program
– managements of techniques, purchase, production, non-
conformance, measurement and etc.
– identification and Search, Inspection and Test.
Contents

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• Project Management Process is the process for
management and control to support development
process, and to manage and control the development
process of the project based on various management/
control plans as specified in aforementioned “Project
Management”
• The basis of this "Manage" and "Control" is Safety
and Mission Assurance. That is, safety assurance is
the major premise for Mission Success.
• In Controlling Process, the followings shall be
performed under the above circumstances.
① Reliability Program ② Quality Management
③ Configuration Management ④ Safety Management
⑤ Risk Management
1. Project Management Process

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2. Reliability Program
• What is Reliability?
The probability that a system of hardware, software,
and human elements will function as intended over a
specified period of time under specified
environmental conditions. (See NASA-STD-0809.22)
• What is Reliability Program?
Reliability Program is the activities related to
following three items in order to ensure the Reliability
(See JMR-004C)
① Reliability Program Management
② Reliability Engineering
③ Tests and Reliability Evaluation

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2.1 Reliability Program Management
Reliability Program Management is
the following activities related to Reliability Program operation.
(1) Organization
In order to ensure the independency of the Reliability Program function,
Reliability Program organization in project organization is functionally
independent from the operating section such as designing, producing and
testing.
The top of the organization should have proper authority and resources
necessary to carry out his responsibility.
(2) Reliability Program Plan
In order to meet the requirements of the Reliability program specified in the
contract, the reliability program shall be created and maintained, and the actual
program shall be carried out.
(3) Promotion and Surveillance
Promote and audit the reliability activities defined in reliability program plan
(4)Education and Training
In order to meet the requirements of the Reliability program, the staff who are
involved in the reliability program activities shall be educated and trained.

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2.2 Reliability Engineering(1/2)
• Reliability Engineering is technical activities which
ensure the reliability itself. These activities apply the
entire life-cycle from the initial phase of the project
to production/testing, launching and operation.
• Basic concept of reliability design: Contractor shall
pursue to decrease the failure risk to the allowable
level according to the importance and severity of a
failure’s influence on the system.
• Standardization of design practice: Contractor
should use existing standards or specifications when
the use of those standards or specifications is
considered more economical and effective, after
necessary modifications are made to comply with
the reliability, quality, and other requirements
specified in the contract.

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2.2 Reliability Engineering(2/2)
• The main and typical activities are as follows.
(1) Preparation and maintenance of Design specification
(2) Reliability Prediction
(3) FMEA (Fault Mode Effect Analysis)
(4) Identification of Reliability Control Items
(5) Stress Analysis for parts
(6) Worst-case Analysis
(7) FTA (Fault Tree Analysis)
(8) Design Review

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2.2.1 Preparation and maintenance of Design specification
(1) The design specification is a document which
contents are broken down for specific designing
based on the development specification, and
includes the followings.
・Requirements related to performances, operations
and environments.
・ Requirements for the test under the specified
stress level.
・Design margin／Derating factor
・Reliability requirements in quality and in quantity
under the specified environments.
(2) This specification should be prepared in the initial
phase of the development and kept up-to-date in
each phase.

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2.2.2 Reliability Prediction (1/2)
Why you need Reliability Program?
• You can not repair or maintain the satellite on orbit.
• The satellite should work for the expected period of time.
• You must decide the end of life's survival probability of
the satellite.
0%
20%
40%
60%
80%
100%
0 2 4 6 8 10
Satellite Design-A
Satellite Design-B
Survival Probability 74% after 3years
60% after 5years
(If you launched 100 satellites,
you lost 40 satellites after 5years )
f(t)=exponential(-λt)
λ:Failure Rate
t:years

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2.2.2 Reliability Prediction (2/2)
• Typical reliability prediction models
◆series model
R1 R2 R=R1*R2
◆parallel model
R=1-(1-R1)*(1-R2)
R2
R1
◆complex model
R1 R2
R4
R3
R6
R5
R7
R=R1*R2*(1-(1-R3)*(1-R4))*(1-(1-R5)*(1-R6))*R7

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2.2.3 FMEA/ FMECA (1/2)
• The possible failure mode of elements in the
early phase of designing and the influence
rate which the failure may affect the target
mission shall be analyzed (Bottom up failure
detection).
• The purpose of the analyze is for the designer
or the designing section to eliminate the
critical design failure mode based on the
analyzed results.
• Single point failure, critical items and critical
characteristics shall be identified, and
recovery plans shall be established.

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2.2.3 FMEA/ FMECA (2/2) ・worksheet
See ECSS-Q-ST-30-02C, Failure modes, effects (and criticality) analysis
Failure Modes and Effects Analysis (FMEA)
Product: System: Subsystem: Equipment
Identificationnumber
Item/block
Function
Failuremode
Failurecause
Missionphase/
operationmode
Failureeffects
a.Localeffects
b.Endeffects
Severityclassification
Failuredetection
method/observable
symptoms
Compensating
provisions
Recommendations
Remarks

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2.2.4 Identification of Reliability Control Items
• To ensure the reliability, important
characteristics to be controlled shall be
identified at each phase of production,
inspection, test, maintenance and operation,
and listed and managed as Critical Item List
(CIL) and/or Reliability Critical Item (RCI).

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2.2.5 Stress Analysis for Parts, Worst-case Analysis
• Stress Analysis for Parts ：
– For use of EEE Parts (Electrical Electronic and
Electromechanical parts) used for electrical
circuits, the applied stress in the required
environmental conditions and operational
conditions shall be analyzed to determine whether
the parts could withhold the stress.
• Worst-case Analysis ：
– For the design characteristic values with possible
performance deterioration during the mission, the
worst-case environmental conditions such as
aging variation, temperature and radiation during
the mission shall be analyzed to determine
whether there are appropriate design margins.

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2.2.6 FTA(Fault Tree Analysis）
• Prior analysis：
A potential important failure mode shall be selected
as a top (the treetop) event and deployed into
developmental pathways to identify the ultimate root
event and examine the probability of occurrence, etc.
The objective of this analysis is to reflect the results in
design optimization, manufacturing/testing plan and
operation.
• Post analysis：
Post analysis is performed to determine the
nonconformance occurrence route, and reflect the
results through remedial actions and
countermeasures.

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2.2.7 Example of FTA
Top failure mode
Primary factor
Secondary factor
Loss of human life
Sinnsuke Akagi, system engineering,Kyoritsu-press(1999) p110
No lift-up
shock fire
Lifting Jig
failure
No self lifting
Lifting Jig failure
>800
kg
No environment control
Container
leak
Wire
tangling
Dumping
jig
failure
Break of wire Failure of
lifting wire
of mother
ship
Improve-
ment of
lthe ifting
equipment
Use of
more
strong
wire
Change to
strong
connector
Deformation of connector
No separation of connector Rupture of
connector
Use of
more
strong
guide wire
Break of
guide wire
Ill-positioning
of submarine
Change to
proper
operation
Use of
thin wire,
Proper
Operation
Big tide
Water
pressure

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2.2.8 Design Review
• Objectives：
– To ensure that the development model complies
with all the development specifications and design
specifications.
• Review documents：
– Design and analysis reports, drawings, compliance
matrix to requirements and etc.
• Review meeting：PDR, CDR, PQR and etc.
– The Reliability Program organization and related
departments shall ensure the accuracy and
completeness of the design review reports. The
Reliability Program organization shall also follow up
on action items to confirm their satisfactory
completion.

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2.3 Testing and reliability assessment
• To ensure the compliance of the items which are
manufactured on the base of the design
specifications to requirements in design
specifications and to evaluate their reliabilities. This
is imperative verification activity to confirm the
availability as the flight items.
（１）Preparation of reliability assessment plan：
– Means of verification(test, inspection, analysis, etc.) of
compliance to requirements in design specification,
Reliability analysis, CIL/RCI.
（２）Test plan：
– Verification of function, performance, durability of the
item under the variety of the environment loads, and etc.

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3. Quality Management Program
What is Quality Management?
Quality Management is various process and tasks to improve
the quality where the production process is managed to see if
it is properly operated. (See JAXA Quality Program Standard
JAXA-JMR-005A)
(1) Planning of Quality Assurance Program
(2) Technical Management
(3) Identification and Search
(4) Purchase Management
(5) Production Management
(6) Inspection and Test
(7) Non-conformance Management
(8) Record of Items
(9) Measurement Management
(10) Marking of Item Conditions
(11) Stamp Management
(12) Establishment of Procedure, Documentation and
Implementation

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3.1 Planning of Quality Assurance Program
(1) Planning of Quality Assurance Program
• Plans for organization, quality record, quality
information report, quality review, education and
training shall be clarified in Quality Assurance
Program.
• Especially, organization shall be functionally
independent from the operational sections such as
design, production and testing in order to ensure the
independency of the quality management function.

(2) Technical Management
• The technical documents (preparation,
maintenance and review) and changes to the
technical contents of designing, production,
testing and inspections shall be properly
managed.
• The suitably assigned role for quality assurance
section in each review board shall be required.
（ Technical documents）
– Technical instruction documents such as
specifications, design documents, plans, and
drawings.
– Fabrication instruction documents such as process
charts, work standards and written procedures.
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3.2 Technical Management

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3.3 Identification and Search
(3) Identification and Search
• Implementation of identification methods such as part number,
dating code, lot number and serial number, etc. for products and
management of IDs and ensuring of traceability shall be
performed.
• Establishment and maintenance of the management system
which could look up the specific component by identification within
the identification list are required as well as the preparation of
identification list based on the identification method.
（Traceability）
– Quality assurance records on the articles and materials shall
identify the part or type number to ensure their traceability to
show parts or materials used in fabrication, as well as to show
locations of the same article models and materials used in the
same fabrication process or in the same assembly.

25
3.4 Purchase Management
(4) Purchase Management
• Purchase Management is activities related to selection of
contractor, review of purchased documents, quality assurance
activities for contractors and acceptance inspection.
• Confirmation using records that include previous qualitative and
quantitative information that will ensure the quality of articles and
materials being procured or of a similar article-type being
procured.
• Implementation of a pre-order survey of the supplier’s facility and
quality assurance system, as well as the status of the quality
assurance to determine if the supplier is capable of satisfying
quality requirements regarding articles and materials based on
the contract and the quality assurance program requirements, or,
confirmation using survey records conducted by the official
certification organization.

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3.5 Production Management
(5) Production Management
• Production Management is activities to record production
process, evaluate the quality at each process (detecting
abnormality by data monitoring), manage the items and goods
to be included in the production instruction document and
establish and maintain the production process.
– Record the fabrication tasks：
1)monitor the important quality characteristics and important
processing parameters of the critical items per the Reliability
Program and maintain these records.
2)compared to previous similar items.
– Fabrication instructions：Nomenclature and identification
number of the article/fabrication equipment/Characteristics
and tolerance/procedures for controlling processes/etc

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3.6 Inspection and Test
(6) Inspection and Test
• Inspection and Test are the activities to plan the
tests and to prepare test specification, inspection
procedure and records as quality assurance
section.
• Quality assurance activity at test
– Task briefing meeting before testing, Joint
confirmation in testing and task review meeting
after testing.

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3.7 Non- conformance Management
(7)Non- conformance Management
– For identification, separation, and corrective actions in the
case of non-conformance products, establishment and
maintenance of proper corrective system shall be required.
– Investigation of the cause, analysis, being handled by
Material Review Board (MRB) and corrective actions shall
be specified.
PR-1：
The designated board
member of the quality
assurance shall review
the noncompliance
and select the
disposition.
PR-2：
The designated QA
member and the
engineer responsible
for designing shall
review and select the
disposition.
MRB：
Representatives of
QA and engineering
section, and JAXA
inspector shall review
and select the
disposition.
disposition ： rework, repair, scrap, use as is, return to supplier,
submission to upper review board (PR-2,MRB).

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3.8 Record of Items & Measurement Management
(8)Record of Items
– For the history or traceability of items, recording of the
data of a series of operations from production, testing,
inspection to corrective actions shall be required.
(9)Measurement Management
– To assure the objectivity of the results of the test and
inspection, acceptance, evaluation, modification and
recording of the measuring devices or equipment shall be
specified.
・Document Package
– Document Package shall be attached to the shipping
product, which consists of the equipment log, the list of
components with limited life, the noncompliance historical
log, the records of inspection and testing and so on.

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references
1) Sinnsuke Akagi, system engineering,Kyoritsu-press(1999)
2) ECSS-Q-ST-30-02C,Failure modes, effects (and criticality)
analysis(2014)
3) JMR-004C,Reliability Program Standard (2012)
4) JMR-005A,Quality Assurance Program Standard (2008)
5) IAQG reference document list,
http://www.sae.org/iaqg/publications/standarda.htm

Textbook for Space Development March 2015: First Edition

Introduction-for_management_program(part_1)

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