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Project Plan Root Cause and Risk Analysis Team 2. NASA: Henning Leidecker; 301-286-9180 Boeing: Gary W. Bickel; 714-372-6820 2/25/00. Team 2 Members. Project Leads: Henning Leidecker-NASA/GSFC Gary W. Bickel-Boeing/HB Team Members: Ray Prestridge-JSC

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project plan root cause and risk analysis team 2

Project PlanRoot Cause and Risk AnalysisTeam 2

NASA: Henning Leidecker; 301-286-9180

Boeing: Gary W. Bickel; 714-372-6820

2/25/00

team 2 members
Team 2 Members
  • Project Leads: Henning Leidecker-NASA/GSFC
          • Gary W. Bickel-Boeing/HB
  • Team Members: Ray Prestridge-JSC
          • Pete Mueggler-BHB
          • Carol McDonald-BHOU
          • Anna Cantwell-SEA
          • David Gill-BHB
          • Jeanette Plante-GSFC
          • Dave Rothermel-BICC
          • Dale Zevotek-BICC
          • Martin Seifert-LSFT
          • David Beverly-JSC
          • Craig Mueller-AERO
          • Harold Battaglia-BHOU
          • John Canham-GSFC
task 1 root cause analysis
Task 1-Root Cause Analysis
  • Identify Primary Agent for “Rocket Engine Defect”--complete: HF-etch enabled by Polyimide void and carbon coating breech
  • Investigate Strength Reduction, ‘96 Cable--complete: 124/446 samples below Proof-Test level; Polyimide void consistently observed
  • need to complete microphotographs on approximately 34 samples
  • Investigate Strength Reduction, ‘98-9 Cable--partially complete
  • Determine source of Polyimide coating voids (fiber or other process)
  • Determine Agent (or process step) for carbon coating breech
  • Resolve Lingering Questions (Polyimide Canyons versus voids, SEM)
  • Complete Root Cause Analysis Report
task 1 root cause status
Task 1-Root Cause: status
  • Microphotos on 34 Samples-deferred
  • Strength Tests 98-9 Cable-on hold
  • Polyimide Coating Voids Source: no progress
  • Coating Penetration Test Plan in development
  • SEM to sort variations in Polyimide void structure: no progress
  • Root Cause Report: Major sections left to write
task 2 risk analysis us lab and node 1
Task 2-Risk AnalysisUS Lab and Node 1
  • Estimate Potential Failures due to Rocket Engine Defects--
  • Determine Effective “n” value--failed; insufficient data
  • Determine alternate model for failure prediction of existing defects/flaws
  • Estimate pre-flight and on-orbit failures based on strength distribution data
  • Determine Potential for Post-Process defect generation by Launch vibration impact
  • Determine Potential for on-orbit defect generation by Ionized Radiation
  • Prepare Risk Analysis Report for US Lab and Node 1
task 2 risk analysis status us lab and node 1
Task 2-Risk Analysis: StatusUS Lab and Node 1
  • Preliminary Risk Analysis Completed
  • No consensus on Preliminary Risk Analysis based on “worst case” n-value
  • Preparing proposal to do n-value tests for ESD attack on uncabled fiber
  • Efforts on vibration/ionizing radiation launch & on-orbit effects on-going
task 3 risk analysis reduction node 1 dt0 cable esa cable all 98 9 cable use
Task 3-Risk Analysis & Reduction(Node 1 DT0 Cable, ESA Cable, all ‘98-9 Cable Use)
  • Determine Low Strength Distribution for ‘98-9 cable--
  • Provide Preliminary Strength Tests on ESA Cable (representing ‘97 production)--
  • Determine Effect of additional “Proof Testing” at the Cable level
  • Apply results of above in estimating risk
  • Prepare Risk Analysis Reports as needed for these tasks
task 3 risk analysis reduction status node 1 dt0 cable esa cable all 98 9 cable use
Task 3-Risk Analysis & Reduction: Status(Node 1 DT0 Cable, ESA Cable, all ‘98-9 Cable Use)
  • Strength Tests on 98-9 cable on hold
  • Tests on ESA cable pending receipt of cables and funding decisions
  • Proof Testing fixture in development