Consensus Standards

1. Presentation of Consensus Standards By Jim Kabbara, AVS – AIR120 MMPDS Chair April 16, 2013

2. The first set of points is related to a first exposure to general engineering standards. 1) What are engineering or consensus standards? 2) Who writes them and who establishes them? 3) Who uses them? 4) When should an engineer use them? What are the obligations to use them? 5) Can engineering standards change in time? 6) Why do we have US and international standards? Which are relevant in any given circumstance? 7) Why do we have to pay for them?

3. The next set of issues is related to using standards. 1) How does an engineer find the standards relevant to the specific problems he or she is addressing? 2) What is involved in using a standard? 3) How much flexibility do engineering standard leave to the practitioner? 4) What are the legal issues related to using or not using engineering standards?

4. Agenda • History of standards • Type of Standards • Examples of Voluntary Consensus Standard • Legal Enforcement • Questions

5. From our beginning as civilized people, we have struggled to harness nature and measure what we have. We’ve developed standards to ensure that whatever we are making; be it a spear, a pyramid, a machine tool, airplane, or spaceship is made to the right dimensions/standard and works as it should.

6. About 3000 years ago, the Greeks learned about measurement from the Egyptians. One of the reasons for the French Revolution was the abuse of weight and measurement. In 1790, The new French government established the meter as one ten million of the distance from the North Pole to the Equator ( of course, through Paris!) • The Small Egyptians cubit became the Greek foot with 16 divisions • The Roman foot followed and was slightly shorter than the Greek foot. King Henry I of England standardized measurement in 1120 decreed the “ell” to be the length from the point of his nose to the end of his thumb leading to the iron ulna as England's standard yard.

7. + (1760 -1830 ) (1870 – The first industrial revolution (1760 -1830 ) brought by the steam engine coupled with the adaptation of interchangeable parts and the second industrial revolution fuelled by locomotive transportation and technological and scientific advance in steel, chemicals, and petroleum along with the invention electricity and telegram caused a paradigm shift from One person making a tool/product from start to finish, where there was little need for a universal standard, to Groups of people/Nations collaborating to make more complex tools/machines/devices where they needed a universal process/way as a means to communicate with one another. 1914) (1994 – ?)

8. What is the distinction between a standard and standardization. Standardization Development process by which technical specifications are created that form sufficient common design elements to enable compatible or compliant products or processes. It encompasses a broad range of considerations – from the actual development of a standard to its promulgation, acceptance, implementation and demonstration of compliance. Lack of national standardization • The catastrophic 1904 fire that destroyed • downtown Baltimore—in part because fire • departments from neighboring cities (such as • Philadelphia and Washington, D.C. as well as • units from New York City, Virginia, Wilmington, • and Atlantic City) were forced to stand by helplessly when their hoses couplings did not fit the Baltimore water hydrants —demonstrated the consequences of the persistent lack of interoperability among threaded devices. A uniform Building was developed and adopted by states and municipalities

9. Steam powered the technology of the late 19th century. Boilers and pressure vessels were an innovation that advanced long-range transportation and heavy lifting in ways that had never been possible before. Despite their power, They were temperamental, requiring constant attention and maintenance. Although there were numerous boiler explosions throughout the 19th century, there were no legal codes for boilers in any state in the Union. Undoubtedly one of the most important incidents that proved the need for developing boiler laws was the Grover Shoe Factory Disaster in Brockton, Massachusetts on March 10, 1905. An older boiler, used as a backup during maintenance on the newer model, exploded, rocketing through three floors and the building’s roof. Broken beams and heavy machinery trapped many workers who survived the initial explosion and collapse. Burning coals thrown from the boiler landed throughout the crumbling superstructure, starting fires that were fed by broken gas lines. The explosion resulted in 58 deaths and 117 injuries American Society of mechanical Engineer (ASME), founded in 1880, Having established the Boiler Testing Code in 1884, ASME formed a Boiler Code Committee in 1911 that led to the Boiler & Pressure Vessel Code (BPVC) being published in 1915. The BPVC was later incorporated into laws in most US states and territories and Canadian provinces.

10. American Petroleum Institute (established on March 20, 1919) The National Petroleum War Service Committee, which oversaw this effort, was initially formed under the U.S. Chamber of Commerce and subsequently as a quasi-governmental body During World War I, drilling delays resulted from shortages of equipment at the drill site, and the industry attempted to overcome that problem by pooling equipment. The program reportedly failed because there was no uniformity of pipe sizes, threads and coupling. API took Developed industry-wide standards and the first standards were published in 1924.

11. What is a standard? A standard consists of specific low level mandatory controls to ensure and control consistency. It typically refers to a product—a specification for the composition, interfaces, or characteristics of a given material, such as the quality of a steel rail, the size and angle of a screw thread, or a common measure of electrical resistance. Definition od Standard The National Standards Policy Advisory Committee defined standard as: "A prescribed set of rules, conditions, or requirements concerning definitions of terms; classification of components; specification of materials, performance, or operations; delineation of procedures; or measurement of quantity and quality in describing materials, products, systems, services, or practices."

13. Type of Standards Very Dynamic De Jure De Facto Standard Voluntary Consensus Standards (VCS) Consortia

14. Type of Standards (Cont’d) • De Facto Standards • De facto standards are developed outside the traditional framework and appeal to a more narrow market than standards written by voluntary standards-focused organizations. They do not feature the broad and open participation. They are set informally through emergence of successful design under competition. • Many successful proprietary technologies achieve market success as de facto standards. This generally includes proprietary standards that become ubiquitous through successful product sales that achieve critical mass. • Examples: • Alcoa in early 1900 monopolizing the production of Aluminum • AT&T dominating the Telephone Industry • Windows Microsoft dominating the computer operating system • Apple and its fight with Android system to dominate the cellular.

15. Type of Standards (cont’d) • De Jure Standard • Set formally by government or other authorized organization. They are mandated by regulators at the local, state, federal, or international level. Governments commonly test conformance with mandated standards, and can legally (and at times severely) punish non-compliance. • Examples: • CFR 14, Part 21, 23, 25 • European GSM transmission standards for cellular telephones • American Federal Communications Commission Part 68 rules that govern the telephone terminal equipment

16. § 25.613 Material strength properties and material design values. (a) Material strength properties must be based on enough tests of material meeting approved specifications to establish design values on a statistical basis. (b) Material design values must be chosen to minimize the probability of structural failures due to material variability. Except as provided in paragraphs (e) and (f) of this section, compliance must be shown by selecting material design values which assure material strength with the following probability: (1) Where applied loads are eventually distributed through a single member within an assembly, the failure of which would result in loss of structural integrity of the component, 99 percent probability with 95 percent confidence. (2) For redundant structure, in which the failure of individual elements would result in applied loads being safely distributed to other load carrying members, 90 percent probability with 95 percent confidence. (c) The effects of environmental conditions, such as temperature and moisture, on material design values used in an essential component or structure must be considered where these effects are significant within the airplane operating envelope. (d) [Reserved] (e) Greater material design values may be used if a “premium selection” of the material is made in which a specimen of each individual item is tested before use to determine that the actual strength properties of that particular item will equal or exceed those used in design. (f) Other material design values may be used if approved by the Administrator

18. ANC-5 ANC-5 (Army-Navy-Commerce) published first materials handbook in 1937 as it was recognized that common material properties and joint allowables benefitted the War Industry .

19. Type of Standards (Cont’d) • ConsortiaStandards • Consortia, usually a group of companies that agree to work together to solve a specific market need, also develop standards. Often seen in areas of rapidly developing technologies, consortia standards offer many solutions and may be developed under an accelerated timeframe, but participation in the development process may be limited to members of the consortia and tied to a substantial financial contribution.

20. Type of Standards (cont’d) • Voluntary Consensus Standards (VCS) • Consensus standardization is a process in which technical experts from public, private, and non-profit sectors negotiate the direction and shape of technological. • VCS document arises from an open process that depends upon data gathering, a vigorous discussion of all viewpoints, and agreement among a diverse range of stakeholders. Thousands of individual experts representing the viewpoints of industry, consumer and labor organizations, and government agencies come together to contribute their knowledge, talents, and efforts to standard-setting activities. • Voluntary refers only to the manner in which the document was developed; it does not necessarily refer to whether compliance to the standard is optional or whether a government entity or market sector has endorsed the document for mandatory use. .

21. Type of Standards (cont’d) • Voluntary Consensus Standards (VCS) (Cont’d) • VCS is a decentralized system that is naturally partitioned into industrial sectors and supported by independent, private sector standards developing organizations (SDOs) and conformity assessment bodies. • American National Institute (ANSI), in close collaboration with National Institute of Standards and Technology (NIST), is tasked with accreditation of SDOs. • VCS is created in response to specific concerns and needs expressed by industry, government, and consumers. And it is a voluntary system in which both standards development and compliance are driven by stakeholder needs. • These documents arise from an open process that depends upon data gathering, a vigorous discussion of all viewpoints, and agreement among a diverse range of stakeholders. Thousands of individual experts representing the viewpoints of industry, consumer and labor organizations, and government agencies come together to contribute their knowledge, talents, and efforts to standard-setting activities.. .

22. Type of Standards (cont’d) • Voluntary Consensus Standards (VCS) (Cont’d). • VCS, in some cases, fosters innovation by establishing a baseline for design and performance that will satisfy user requirements. • VCS should provide enough flexibility that suppliers or manufacturers can vary features, function or price to establish their own niche in the marketplace. These variances can help to elevate user expectations of a product or service, thus raising the bar for future editions of the applicable standard. • VCS, when innovation comes first, may establish set of performance or design criteria that are agreed upon and serve as the baseline for ongoing improvements. The VCS becomes the physical documentation of an agreed-upon solution that has already been time-tested and proven.

23. Type of Standards (cont’d) • Voluntary Consensus Standards (VCS) (Cont’d). • The costs of developing and implementing most types of voluntary standards are typically borne by those who will derive benefit from the document. • Certain expenses are assumed by the entity responsible for facilitating the standard's development; • Others expenses are taken by the subject matter experts and organizations that participate in its creation. • The end user bears the cost of purchase, if applicable, and may assume responsibility for implementation expenditures. • The equitable distribution of expenses incurred during the standardization life cycle helps to mitigate the risk that any single group will attempt to exercise undue influence because it has taken on an inordinate share of the expenses.

26. Source: American Standards Association, Voluntary Standards, 1946

27. Metallic Materials Properties Development and Standardization MMPDS Defined

28. History & Background Evolution of ANC-5 to Mil-Hdbk-5 • Mil-Hdbk-5 (published and funded by the Air Force) was first published in 1959. • Original publication took data from ANC-5 and expanded content. • Recognized that a single published source of material properties was cost effective, encouraged companies to share their data for the benefit of all and resulted in increased product safety. • Air Force funding was used along with industry money in development of material properties to fill in gaps in the data.

29. History & Background Evolution of Mil-Hdbk-5 to MMPDS • With acquisition reform of the early-mid 90’s the Air Force withdrew from the specification business and Mil-Hdbk-5 transitioned to MMPDS with the Federal Aviation Administration (FAA) as lead government agency. • The USAF issued a cancellation notice for MIL-HDBK-5J, effective May 5, 2004.  In the notice, a pointer is made to the MMPDS-01 as the replacement document. • Initial issue MMPDS-01 was identical to the last issue of Mil-Hdbk-5. • MMPDS-06 recently published

30. Overview MMPDS Handbook MMPDS is the result of technical coordination activity of industry-government collaborative process in which consistent and reliable methods are developed and used to collect, analyze, and present statistically based material and fastener allowable properties. This activity was originally established to develop consensus standards for metallic materials and fastener system properties and the methods used to develop them. As such, the MMPDS Handbook is recognized and used by engineers worldwide as the primary source of statistically-based design allowable properties for metallic materials and fasteners used in many different Aerospace Launch Vehicles, commercial aircraft and military weapon systems around the world.

31. Overview Types of Data in MMPDS Fatigue Stress-Strain Curves Design Allowable Mechanical Properties Effect of Temperature Fracture Toughness Joint Allowables

32. Overview

33. Overview

34. Overview Graphical Data Examples Effect of Temperature Fatigue Stress-Strain Curves

35. Data Entry Requirements Overview • Production material manufactured using production facilities, standardized fabrication techniques and processing procedures • Material conforms to a material specification: • Industry: ASTM, SAE-AMS • Government: Military, Federal • Testing procedures conform to ASTM standards and specifications

36. Overview Review and Approval Process

37. Overview Final Requirement Output • What is the outcome: A standardized process to develop acceptable design and certification compliance data and tools that enable the FAA to operate in more cost effective and efficient manner • How will it be used: Promote a uniform level of safety in developing and maintaining safety standards through a widely recognized government/industry organization • What will it be used to accomplish: MMPDS Handbook data and guidance material to comply with requirements for material properties and design values.

38. MMPDS Organization • MMPDS reflects combined efforts of Industry and Government Industry Steering Group Government Steering Group Airframer Working Group Material & Tech Working Steering Group General Coordinating Committee Propulsion Working Group (new 2012) Secretariat (Battelle) Materials Task Group Guidelines Task Group Fasteners Task Group

39. MMPDS Organization (cont…) MMPDS reflects combined efforts of Industry and Government Industry Steering Group Government Steering Group Airframer Working Group Secretariat (Battelle) Propulsion Working Group (new 2012) Government Steering Group (GSG) provides oversight to ensure that values published meet regulatory requirements. Industry Steering Group (ISG), in partnership is other industry special interest groups, define what materials & properties are needed to be included in handbook to ensure MMPDS supports industrial needs. The Secretariat, with guidance from the GSG & ISG, performs the day-to-day tasks to keep MMPDS current. (e.g., data regression, MMPDS publication, coordinating meetings, etc…)

40. MMPDS Partnerships FAA organizations: AIR-100, ANM-100, ANG-E2: SIC-TCRG Other Government organizations Industry (Mainly Aircraft Industries) Academia International MMPDS Organization

41. MMPDS Organization GSG Membership • Ideally represent all government agencies that derive benefits from the existence and continued maintenance of MMPDS Handbook. • Depending on the availability of funds, support has been provided from various agencies including the Defense Logistics Agency (DLA), USAF, NASA, Navy, and the FAA. • Current dues paying members are FAA ($) & Navy ($K)….

42. ISG Membership MMPDS Organization • Representatives from major metallic material suppliers and users worldwide • Membership growing: From 10 to 29 organizations past 5 years • International Participation: • Canada • France • Germany • Japan • Romania • Spain • Turkey • UK • USA

43. MMPDS Organization • Meetings held twice/year; spring & fall • Agenda items presented at meetings for revision of MMPDS • New Alloys • Revision to guidelines • Revision to existing mechanical properties • Addition of other properties; fatigue, effect of temperature curves, fracture toughness, creep, etc • Task Groups review agenda and determine revisions to next MMPDS Handbook • Finalized/formalized at General Coordinating Committee

44. Summary • Industry/Government collaborative process • Results in consensus standards for: • Material Allowables • Statistical Methods • Facilitates compliance with 14 CFR (civil), JSSG 2006 (military ) and NASA-STD-6016 (NASA) Allowables Data Statistically-Based

45. Summary Evolving Process and Document • Data entered for new materials and fastener systems: Up to 6 new alloys are added to each handbook revision • Data is continuously evaluated, critiqued and updated: Statistical procedures and guidelines • Maintained by an unbiased third party secretariat (Battelle)

46. Legal Ramification & Enforcement • De Facto Standards • Unless been codified, Government can enforced or take legal action. • May be liable for civil lawsuits • De Jure Standards • Congress bestows on Federal Agencies to enforce and take legal action Voluntary Consensus Standards (VCS) Standard • Public Application • It has be used as used and referenced in Agency standard. e.g. TSOA (Technical Standard Order Authorization), AC (Advisory Circular) • Civilian Application • May be liable for civil lawsuits § 21.2 Falsification of applications, reports, or records. (a) A person may not make or cause to be made: (1) Any fraudulent, intentionally false, or misleading statement on any application for a certificate or approval under this part; (2) Any fraudulent, intentionally false, or misleading statement in any record or report that is kept, made, or used to show compliance with any requirement of this part; (3) Any reproduction for a fraudulent purpose of any certificate or approval issued under this part. (4) Any alteration of any certificate or approval issued under this part. (b) The commission by any person of an act prohibited under paragraph (a) of this section is a basis for: (1) Denying issuance of any certificate or approval under this part; and (2) Suspending or revoking any certificate or approval issued under this part and held by that person. [Doc. No. 23345, 57 FR 41367, Sept. 9, 1992, as amended by Amdt. 21-92, 74 FR 53384, Oct. 16, 2009; Amdt. 21-92A, 75FR 9095, Mar. 1, 2010]

48. Standards play major role in preventing loss of lives and properties of the right standard and to ensure compliance with its requirement

49. The first set of points is related to a first exposure to general engineering standards. 1) What are engineering or consensus standards? 2) Who writes them and who establishes them? 3) Who uses them? 4) When should an engineer use them? What are the obligations to use them? 5) Can engineering standards change in time? 6) Why do we have US and international standards? Which are relevant in any given circumstance? 7) Why do we have to pay for them?

50. The next set of issues is related to using standards. 1) How does an engineer find the standards relevant to the specific problems he or she is addressing? 2) What is involved in using a standard? 3) How much flexibility do engineering standard leave to the practitioner? 4) What are the legal issues related to using or not using engineering standards?