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1. NASA Engineering and Safety Center (1)

2. NASA Engineering and Safety Center Agenda • NESC Overview Mike Hagopian • SPRT Overview Frank Bauer • NESC Processes Bob Kichak • NESC Pathfinders • Rudder Speed Brake Bob Kichak • X-43 Frank Bauer • Calipso Mike Hagopian • MER Frank Bauer • Recent Activities • Shuttle Anomalies; Flowliner Mike Hagopian • ISS CMGs; Cassini; Genesis Frank Bauer • FPGAs; Data Integrity Bob Kichak

3. NASA Engineering and Safety Center Overview Mike Hagopian

4. NASA Engineering and Safety Center • On July 15, 2003, Administrator O’Keefe announced plans to create the NASA Engineering and Safety Center at Langley Research Center. The Center will provide a central location to coordinate and conduct robust, independent engineering and safety assessments across the Agency.

5. NASA Engineering and Safety Center • Charter approved by Executive Council on August 1, 2003 • Management Plan approved October 3, 2003 • Operational on November 1, 2003 • Four path-finder assessments conducted • Several Independent Technical Assessments and Consultations on-going

6. NASA Engineering and Safety Center “ … I named my spacecraft Sigma Seven. Sigma, a Greek symbol for the sum of the elements of an equation, stands for engineering excellence. That was my goal – engineering excellence. I would not settle for less …” From “Schirra’s Space” by Wally Schirra NESC’s Goal is Engineering Excellence – We will not settle for less!

7. NESC philosophy and culture Safety through Engineering Excellence Mission Success Starts with Safety Safety Starts with Engineering Excellence NASA Engineering and Safety Center NESC will cultivate a Safety culture by providing knowledgeable technical leadership to perform independent in-depth technical assessments in an open environment with unequalled tenacity.

8. NASA Engineering and Safety Center What problem are we trying to solve? “The safety organization sits right beside the (shuttle) person making the decision, but behind the safety organization there is nothing there, no people, money, engineering, expertise, analysis.” “ … there is no ‘there’ there” Adm. Harold Gehman (1)

9. NASA Engineering and Safety Center • Problem: NASA lacks “value added” independent assessment of technical issues within its programs and institutions. • Our safety philosophy has 3 tenets • Strong in-line checks and balances • Healthy tension • “Value added” independent assessment • Example Solutions: Large complex problems are solved utilizing “One NASA” philosophy under emergency tiger team approach. • Flowliner, BSTRA, Columbia Accident Investigation

10. NASA Engineering and Safety Center Challenge: How do we maintain this “One NASA” Tiger Team approach to provide our programs and institutions much needed independent assessment? Proposed Solution: • Establish a NASA Engineering & Safety Center (NESC) • Establish a small NESC management office at LaRC

11. NASA Engineering and Safety Center Proposed Solution: (cont’d) • Decentralized organizational structure across all Centers reporting to the NESC management office • Engineers need to be where the problems are to stay sharp • Strong systems engineering function for independent trending and systems engineering analysis • Small core of engineering experts for insight into respective programs • Select and promote best engineers to “dig” for issues and trends

12. NASA Engineering and Safety Center Proposed Solution: (cont’d) • Use “ready” experts at each Center through formal task agreements • Establish Super Problem Resolution Teams (SPRTs) by discipline • Select recognized Agency discipline experts to lead SPRTs • Pool senior engineering resources to attack “trouble spots” • Overcome negative connotation of IA by offering our best technical expertise • NESC gains its independence by being funded at the Agency level

13. Independent Assessment Agency-wide GS15, ST, SL, SES NESC GS14-15 , ST, SL, SES Senior Engineers In-line Functions Programs and Institutions Junior Engineers GS9-13 Co-Ops, Interns, Freshouts GS5-7 NASA Engineering and Safety Center Proposed Solution: • Establish natural hierarchy of engineering progression • Engineers must aspire to be in the NESC • Challenging work, visibility, pay and promotion

14. GNC - NDE - Propulsion - Power & Avionics - Mechanical Analysis - Flight Sciences - Mechanical Systems - Human Factors - Materials - Structures - Fluids/Life Support/Thermal - Software - Frank Bauer (GSFC) Dr. Ed Generazio (LaRC) George Hopson (MSFC) Robert Kichak (GSFC) Julie Kramer (Acting) (JSC) Steve Labbe (Acting) (JSC) John McManamen (JSC) Dr. Cynthia Null (ARC) Dr. Robert Piascik (LaRC) Dr. Ivatury Raju (LaRC) Henry Rotter (JSC) Steve Scott (GSFC) Office of the Director Director - Ralph Roe Deputy Director - Dr. Paul Munafo Deputy Director for Safety - Larry Crawford SMA Integration - John Tinsley (HQ) Chief Astronaut - Dr. Steve Hawley (JSC) Chief Scientist - Dr. David Leckrone (GSFC) NESC Leadership Team/ NESC Review Board LaRC Management & Technical Support Office Systems Engineering Office Principal Engineers Office Ken Cameron Clinton Cragg Dr. Richard Gilbrech Dr. Charles Harris Manager – Ralph Roe (Acting) Manager - Stan Newberry LaRC LaRC LaRC NESC Chief Engineers Office NESC Discipline Experts Office GRC - Derrick Cheston ARC - Dr. Michael Freeman SSC - Randy Galloway LaRC - Dr. Michael Gilbert GSFC - Michael Hagopian JSC - David Hamilton MSFC - Danny Johnston DFRC - Michael Kehoe JPL - Matt Landano (Acting) KSC - Tim Wilson NASA Centers NASA Centers

15. NASA Engineering and Safety Center Number of NESC Leadership Team personnel from each Center External - 2 3 leadership positions yet to be filled GSFC - 5 GRC - 1 HQ - 2 LaRC - 6 ARC - 2 DFRC- 2 JPL - 1 MSFC - 3 SSC - 2 JSC- 4 KSC - 1

16. NASA Engineering and Safety Center Discipline Super Problem Resolution Team (SPRT) Introduction and Staffing Frank H. Bauer Mission Success Starts With Safety • Safety Starts With Engineering Excellence

17. NASA Engineering and Safety Center • NASA lacks “value added” independent assessment of technical issues within its programs and institutions. • NESC created to provide independent assessment of technical issues • Scope • Independent in-depth technical assessments • Independent trend analysis • Independent systems engineering analysis • Mishap Investigations • Support Programs • Focus on High Risk Programs • NESC independent assessment uses discipline experts from across NASA and Nation in Super Problem Resolution Teams

18. NESC Principles of Operation • Proactive – Test and analysis of issues or trends not currently being addressed by the program • Active – Independent review of known risk areas • Reactive – Independent investigation of mishaps and close calls • Set example for safety culture through engineering excellence • Encourage/document /disposition dissenting opinions • Measure performance with metrics

19. NESC Personnel / Staffing • NESC permanent staffing includes: • Principal Engineers located at NASA Langley • NESC Chief Engineers (NCE) located at each NASA Field Center • Systems Engineers located across the Agency • NESC Discipline Experts (NDE) for specific disciplines located across the Agency • Fluids/Life Support/Thermal, Flight Sciences, Guidance Navigation & Control, Human Factors, Materials, Mechanical Analysis, Mechanical Systems, Non-Destructive Evaluation, Power & Avionics, Propulsion, Software, Structures • Chief Scientist & Chief Astronaut • NDE’s, Chief Scientist & Chief Astronaut are the leaders of National expert teams…called Super Problem Resolution Teams (SPRT)

20. SPRT’s • SPRT’s are the backbone of the NESC • SPRT’s shall have membership from multiple sources • NASA, industry, academia and other Government Agencies • SPRT’s will provide technical support of NESC assessments • Independent expertise/reviews and leadership • Independent test, analysis and evaluation – not just technical opinions • NESC Discipline Experts working with NASA leadership to identify SPRT membership for each specific discipline • Changes/additions to SPRT’s will be negotiated with the respective NASA Centers/organizations, as required

21. Structures Discipline Expert GN&C Discipline Expert NDE Chief Discipline Expert TBD Discipline Expert ARC DFRC GRC GSFC JPL JSC KSC LaRC MSFC Stennis DOD University National Labs Consultants ARC DFRC GRC GSFC JPL JSC KSC LaRC MSFC Stennis DOD University National Labs Consultants ARC DFRC GRC GSFC JPL JSC KSC LaRC MSFC Stennis DOD University National Labs Consultants ARC DFRC GRC GSFC JPL JSC KSC LaRC MSFC Stennis DOD University National Labs Consultants NASA Engineering and Safety Center NESC Discipline Expert Super Problem Resolution Teams (SPRT’s)

22. SPRT Discipline Team Model SPRTNESC Discipline Expert Core Team Members Sub-discipline Experts Technical Team Support SPRT Discipline Team

23. Team Roles & Responsibilities Expectation: Several discipline SPRTs running concurrently • Core Team Members • Provide discipline leadership to SPRTs • Knowledgeable of several sub-disciplines within SPRT (e.g. for GN&C could be attitude control, gyros, star trackers) • Possess majority of expertise (50-60%) required to resolve SPRT problems • Understanding of I/TAI processes so can effectively communicate these to sub-discipline experts when I/TAI started • Attends bi-weekly SPRT team meeting & face-to-face meetings • Sub-discipline experts • Provide “drill down” expertise in specific sub-discipline (e.g. for GN&C could be gyro expert, star tracker expert, trajectory expert, etc) • On-call to the team • Attends face-to-face meetings (1-2x yearly) • Technical Team Support Engineers • GS-11-13 engineers • Provide support to SPRT team by setting up meetings and teleconferences, take meeting minutes, participate in discussions (observers, not voting members) • Enables junior experts to become part of the NESC process and serves vital team function

24. NESC SPRTs on ITA/Is NESC Director / Review Board (NRB) NESC Chief Engineers (NCE) NESC Principal Engineers (NPE) NESC Discipline Experts (NDE) • ITA/I Team – NESC led team of independent experts conducts independent test, analysis and inspection on selected requests • Primarily Led by NPE • Could be NDE or NCE • Comprised of Discipline SPRT experts Independent Technical Assessment / Inspection (ITA/I) Team Super Problem Resolution Team (SPRT) Core • SPRT Tech Experts – Roster of focused discipline experts with skills / capabilities in a particular field of the discipline • Conduct Test, Analysis, Evaluations in their field of expertise in support of NESC ITA/Is • Readily Accessible • Considered the Best of the Best • Matrix support to NESC as Requested • On Call to Support an IAT/I • Time / resources covered by NESC PWC • SPRT Core – 10 to 20 experts with broad based experience and knowledge across the range of the discipline • Regular SPRT Telecons (bi-weekly • Peer Review of IAT/I Products • Think Tank for Discipline • Annual Working Group Meetings • Low Level Continuous Support to NESC • Time Covered via NESC PWC • On Call to Support an IAT/I SPRT Tech Experts (NASA) SPRT Tech Experts (Other Govt. Agency) SPRT Tech Experts (Industry) SPRT Tech Experts (Academia)

25. Benefits to being an SPRT Member • Provides an opportunity to interact with the best of the best in NASA, Industry, Academia and other Government Agencies • Challenging assignments & interaction with discipline experts • Invaluable Experience gained helping resolve NASA’s critical issues • High Impact / High Feedback / High Visibility / Job Satisfaction • Growth through addressing broad spectrum of technical issues and gaining experiences within chosen discipline • Problem Resolution Team is a challenging experience • Recognition and Interaction within technical discipline

26. Benefits to being an SPRT Member (cont.) • Exposure to other NASA programs, projects, cultures, methods, business practices across the agency • Potential career development experiences and opportunities • NESC is pursuing human resource initiatives and benefits to supporting NESC • Provides a review team for Programs and Projects members to identify their own project concerns and issues for the SPRT to review and decided if further study/review is required

27. Organization Benefits of Supporting NESC • Provides employees opportunity to interact with the best of the best in NASA, Industry, Academia & other Government Agencies • Comprehensive expertise obtained through NESC agency level experience broadens employees technical experience • Across full spectrum of discipline • Provides a better employee through this experience • Teaches method for problem resolution and how to obtain corrective actions • Lead & Participation in a “OneNASA” initiative • Exposure to other NASA programs, projects, cultures, methods, business practices across the agency • Broadens employee horizons via wide network of interaction • Gains experience outside employee’s own work area • Potential for NESC funding • Recognition of Discipline Expertise within your center/organization

28. NESC Processes Bob Kichak

29. NASA Engineering and Safety Center NESC Processes • Independent Technical Assessments • Technical Inspections • Technical Support • Technical Advocacy • Selection & Prioritization • NESC Review Board • Knowledge Capture and Communication • Mishap Investigation • Dissenting Opinions • Awards

30. NRB Executive NESC Review NESC Director Secretary Board (NRB) Start 1.1 1.2 Prepare draft Review, Agenda & Approve, or Submit for Modify Approval 1.3 Distribute final Agenda 1.4 1.5 Assemble All Review Materials for Agenda & Review & Posted Post Materials 1.6 Convene NRB 1.7 Participate in NRB & Provide Recommend- ations 3.0 Document and Disseminate NRB Products NASA Engineering and Safety Center NESC Processes • All requests are catalogued and tracked through disposition • Multiple sources for requests • Insight of NESC members • Participation in program boards and panels • Independent trend analysis • Senior NASA Managers • Program/Project Managers or team members • Institutional Engineering and S&MA • NASA employees • NESC Anonymous Reporting System • Phone calls/emails • NSRS

31. NASA Engineering and Safety Center NESC Processes (cont’d) • NESC Selection Process • Initial request screening completed by Systems Engineering Office • Coarse filter screen • Two-person rule for rejections/referrals • Second screen completed by NESC Chief Engineer (NCE) • Research request • Conduct risk assessment (NARMA) • Board presentation with recommendation • NESC Review Board makes final decision by team consensus • Accept and support with NESC resources (assessments & inspections) • Otherwise, re-direct to another NASA Org • Close-loop notification to customer Independent Funding

32. NASA Engineering and Safety Center NESC Processes (cont’d) • Assessment and Inspection • Teams • Led primarily by NESC Principal Eng or NESC Discipline Experts • Comprised of engineers from discipline Super Problem Resolution Teams (SPRTs) • NASA, industry, national labs, academia and other government agencies • Independent from program or project • Communication • Initial program/project notification • POC identification • In briefs, exit briefs, status reports, and formal engineering reports Independent Team Members

33. NASA Engineering and Safety Center NESC Processes (cont’d) • Reports • Written technical engineering reports • Based on independent test, analysis, and data review • Will include findings, observations, recommendations, and actions • Reviewed and approved by NESC Review Board – peer review • Only products that have been peer reviewed by the NESC Review Board will use the NESC logo and header • Program/project responsible for corrective action and/or reclamas • NESC can provide support if requested • NESC must concur in corrective action plans and will follow-up as appropriate This briefing is for status only and does not represent complete engineering data analysis

34. NASA Engineering and Safety Center NESC Processes (cont’d) • Knowledge Capture and Communication • A list active NESC assessments, inspections and support activities will be posted to the web site • Customers will receive periodic status reports • NESC will share results of investigations and inspections • Programs and projects will have chance to respond to findings and recommendations prior to releasing reports • Final reports will be posted to web site • Lessons learned will be presented at quarterly leadership briefings

35. NASA Engineering and Safety Center NESC Pathfinders

36. NASA Engineering and Safety Center NESC Path-Finder Assessments Orbiter Rudder Speed Brake Actuator Braycote Grease • Requested by Space Shuttle Program Manager • Assessed the potential breakdown of Braycote grease in the rudder speed brake actuators • Discovered planetary gear assembly installed backwards X-43A • Requested through a “dissenting opinion” email to the NESC • Specific technical concerns with several aerodynamic issues in return to flight approach • Worked with project manager to ensure concerns are addressed and properly dispositioned • X-43A a resounding success

37. NASA Engineering and Safety Center NESC Path-Finder Assessments (cont’d) CALIPSO – Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observations • Requested by GSFC Deputy Center Director/Center Director • Assessed human safety risks associated with the possibility of leakage through threaded mechanical fasteners in a mono-propellant system Mars Exploration Rover (MER) Flight Operations • Requested by JPL Safety and Mission Assurance Office • Provided human factors review of flight controller operations and review of entry, descent and landing phases---several recommendations provided to the MER team to improve ops • Assisted in data review following landing of first rover to determine potential impacts to second rover’s entry, descent and landing phases

38. NASA Engineering and Safety Center Recent Activities • Shuttle Anomalies; Flowliner Mike Hagopian • ISS CMGs; Cassini; Genesis Frank Bauer • FPGAs; Data Integrity Bob Kichak

39. NASA Engineering and Safety Center Summary: • NASA established small decentralized NASA Engineering & Safety Center (NESC) • Utilizes existing senior engineering expertise at the Centers, reporting to NESC management office at LaRC---One NASA • Gain independence by funding at Agency level and reporting to Langley Center Director and Codes D and Q • Provide “value added” independent assessment by having the best technical expertise available where it is needed most Safety through Engineering Excellence • Maintain the organization through a natural hierarchy of engineering progression • See the NESC web site for more information: http://nesc.nasa.gov