ML19308B752
| ML19308B752 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 08/31/1974 |
| From: | Malkin M NATIONAL AERONAUTICS & SPACE ADMINISTRATION |
| To: | |
| References | |
| TASK-TF, TASK-TMR NHB-5300.4(1D-1, NHB-5300.4(1D-1), NUDOCS 8001160937 | |
| Download: ML19308B752 (62) | |
Text
_ _ _ _ _.. _.
NHB S300.4 (ID-1)
Aug ust 1974 I*
4 4
RELIABILITY AND QUALITY ASSURANCE PUBLICATION i
i S AFETY, RELI ABILITY,M AINT AIN ABILITY AND QU ALITY PROVISIONS FOR THE SPACE SHUTTLE PROGR AM 9
NATIONAL AERONAUTICS AND '2 ACE ADMINISTRATION
<h 8001160f37
NHB 5300.4(lD-1)
PREFACE Dat':
August 1974 This publication establishes common safety, reliability, maintain-ability and quality provisions for the Space Shuttle Program.
NASA Centers shall use this publication both as the basis for ne-gotiating safety, reliability maintainability and quality require-ments with Shuttle Program con, tractors and as the guideline for conduct of program safety, reliability, maintainability and quality activities at the Centers.
Centers shall assure that applicable-provisions of this publication are imposed in lower tier contracts.
Centers shall give due regard to other Space Shuttle Program plan-ning in order to provide an integrated total Space Shuttle Program activity.
In the implementation of safety, reliability, maintainability and quality activities, consideration shall be given to hardware com-plexity, supplier experience, state of hardware development, unit cost, and hardware use.
The approach and methods for contractor implementation shall be described in the contractor's safety, reliability, maintainability and quality plans.
This publication incorporates provisions of NASA documents:
NHB 1700.1 " NASA Safety Manual, Vol. I"; NHB 5300.4(1A)," Reliability Program Provisions for Aeronautical and Space System Contractors ';
and NHB 5300.4(lB), " Quality Program Provisions for Aeronautical and Space System Contractors."
It has been tailored from the above documents based on experience in other programs.
It is intended that this publication be reviewed and revised, as appropriate, to reflect new experience and to assure continuing viability.
Questions concerning application of this publication to specific procurements should be referred to the procuring NASA Installation.
General questions concerning the intent of the provisions herein should be referred to the NASA Headquarters, Director, Space Shuttle Program, Washington, D.C.
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1 NHB 5300.4(lD) is canceled.
)
M. S. Malkin
- Director, Space Shuttle Program Distribution:
SDL 1 (SIQ) 1
TABLE OF CONTENTS Par.
Page CHAPTER 1: INTRODUCTION 1
1D100 Approach...................................
1-1 1D101 Relation to Other Contract and Program Requirements...... 1-1 1D102 M o t i va t i o n.................................... 1-1 1D103 Independent Evaluations for NASA.................... 1-2 1D104 Information Requirements List (IRL) and Information Requirements Descriptions (IRD's).................... 1-2 CHAPTER 2: SAFETY 1D200 Safe ty M ana g em e nt.............................. 2-1 1D201 Sys te m S afe ty................................
2 - 4 1D202 Indus t rial S afe ty...............................
2 - 9 1D203 T e s t Ope ra tions Safe ty........................... 2-10 CHAPTER 3:
RELIABILITY 1D300 Reliability Managem ent........................... 3-1 1D301 Reliability Engine e ring........................... 3-2 1D302 T e s t in g.....................................
3 - 9 CHAPTER 4: MAINTAINABILITY ASSURANCE 1D400 M a na g e m e nt................................... 4-1 1D401 P rog ram Elem e nt s.............................. 4-1 CHAPTER 5: QUALITY ASSURANCE ID500 Managem ent and Planning.......................... 5-1 1D501 De sign and Development Controls.................... 5-4 1D502 Identification and Data Re trieval..................... 5-7 1D5"3 P r o c u r e m e nt............................
5-9 1D504 Fab ric ation Cont rols.......................
..... 5-17 1D505 Te sting, Inspections, and Evaluations.................. 5-20 1D506 Nonconforming Articles and Materials................. 5-27 1D507 Me t r olo gy,......................
5-33 1D508 S t am p Cont rol s................................. 5-35 1D509 Handling, Storage, Pr eservation, Marking, Labeling, 1-ackaging, Packing and Shipping.................... 5-36 1D510 Sampling Plans, Statistical Planning and Analysis.......... 5-38 1D511 Gove rnment P rope rty Cont rol.............*.......... 5-39 1D512 Flight Te st/G round Ope rations...................... 5-41 Appendix A - Glo s s ary of Te rm s...........................
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CH APTER 1: INTRODUCTION 1D100 APPROACH The safety, reliability, maintainability, and quality assurance activ-ities require:
1 Thorough planning and effective management.
2 Definition of the major s afety, reliability, maintainability and quality assurance tasks and their place as an integral part of the design and development process,
- 3. Evaluation of hardware s afety, reliability, maintainability and quality through analysis, test, review, and assessment.
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Timely status indication by formal documentation and other re-porting to facilitate implementation of the s afety, reliability, maintainability and quality assurance efforts.
5 Compatible requirements among manufacturing, test and opera-tional sites.
1D101 RELATION TO OTHER CONTRACT AND PROGRAM REQUIREMENTS The safety, reliability, maintainability and quality assurance activ-ities set forth in this document shall complement and support other required functions, but duplication of contractor efforts shall not be incurred as a result of overlapping or interfacing requirements con-tained elsewhere in the statement gf work or in other parts of the contract. Interfacing program activities and requirements shall be referenced as part of the contractor's Safety, Reliability, Maintain-ability and Quality Plans. Provisions for fulfilling all requirements of this document shall be included in these plans or in other plans and referenced in the Safety, Reliability, Maintainability and. Quality Plans.
1D102 MOTIVATION The contractor shall maintain a product or oriented motivation (awareness) program planned and implemented as an integral part of, and making maximum use of, his existing motivational effort. The program objective shall be the prevention of humanerror by insti}1ing in individuals performing on the contract and on critical subcontracts thereunder, an awareness of their personal responsibility for Space Shuttle mission success and motivating the exemplary performance 1-1
necessary to achieve this success. The program shall include the i
following as a minimum:
- 1. Goal setting and measurement to provide documented practical goals and performance standards for the reduction and elimination of human errors at organizational and individual employee levels.
- 2. Error Cause Identification and Removal System for detecting human errors, relating thern to an identifiable cause and action to remove the cause.
- 3. Methods to obtain and distribute Space Shuttle motivationiniorma-tion and materials to concerned contractor personnel, those of subcontractors and vendors supplying critical flight and ground support hardware and software.
4.
Motivational (awareness) indoctrination for contractor Space Shuttle supervisory personnel and indoctrination of the work force in workmanship needs.
- 5. Recognition means for personnel who demonstrate their awareness through exceptional craftsmanship, error free workmanship and attention to careful performance in their job responsibility.
- 6. Existing Motivation (Awareness) programs of suppliers of criti-cal flight and ground support hardware / software shall be re-viewed for compliance with the intent of these requirements in motivating supplier personnel and their sub-suppliers to exem-plary performance. Provisions for fulfilling all or part of the requirements on c ritical subcontracts will be authorized by specific contract direction.
1D103 INDEPENDENT EVALUATIONS FOR NASA NASA reserves the right to use representatives of NASA-selected contractor (s) in its evaluations of safety, reliability, maintainability and quality assurance activities. These contractors may:
- 1. Provide technical support to NASA.
- 2. Determine effectiveness of and recommend improvements to sys-tem and subsystem contractor's and supplier's safety, reliability, maintainability and quality assurance efforts.
1D104 INFORMATION REQUIREMENTS LIST (IRL) AND INFORMATION REQUIREMENTS DESCRIPTIONS (IRD's)
Information Requirements List and Information Requirements De.
scriptions shall be included in the contract.
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CH APTER 2: SAFETY 1D200 SAFETY MANAGEMENT The contractor shall maintain a safety activity planned and developed in conjunction with other functions to assure that hazards are identi fied and resolved. In addition to the development of a Safety Plan, safety requirements and tasks will be reflected as appropriate in other Program Plans. Applicable safety requirements and tasks shall be included in the basic management systems, design verifica-tion documents, overall system analyses, and system engineering requirements definition, and design review practices. Major ele-ments of safety management are:
1 Safety Plan. The contractor shall prepare a Safety Plan which complies with the requirements identified in this document. The contractor shall place special emphasis on describing how he will assure the identification, elimination and/or control of potential hazards which lead to injury, loss of personnel and/or damage or loss of flight or ground hardware throughout the complete cycle of the program. This Safety Plan will integrate and describe the relationship of all safety activities. Existing documents may be referenced and submitted as part of the Safety Plan. The Industrial Safety / Occupational Health and Safety Plan shall be incorporated or attached to the Safety Plan. The Safety Plan should provide in a matrix form, or some equivalent format, the clear / concise title of all the specific tasks to be covered by the plan, with the follow-ing additional information about each task,
- a. Other program plans which are ins c1ved,
- b. Contractor organization (s) involved in the execution of each
- task, i
- c. The contractor program procedure / instruction which de-scribes how each task is performed.
- d. The start and completion schedule of each task including pro-gram schedule or milestone which the task supports.
- e. The output products of each task including identification of deliverable data, f.
The resources or manhours required to execute eachtask.
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2 Site Safety Plans. Separate Site Safety Plans shall be prepared prior to construction, activation and/or operations phases of site activities as applicable,
- a. If NAM has a site construction contract with a contractor other than a prime Shuttle contractor, and if the prime Shuttle contractor (s) will be onsite during the construction phase, both/all contractors under NASA sponsorship shall-outline their safety approaches, responsibilities, and inter-faces to assure development of compatible contractor Site Construction Safety Plans.
- b. If NASA's prime Shuttle contractor or his subcontractor has the site construction contract, the responsible contractor shall provide the Site Construction Safety Plan.
- c. These guidelines also apply to remodeling or renovating ex-isting sites and, in a similar manner, to activation and opera-tions phases where contractors are engaged in joint activities.
3 General Considerations. Safety requirements for planning, design,'
manufacturing, testing, and operations shall be developed and documented as an integral part of the contractor's activities. The contractor shall establish check points and feedbacks which pro-vide management visibility to assure that all safety considerations have been evaluated and completed prior to crommencement of major activities or milestones. The contractor shall establish a system to assure that there is compatibility of design, test, and operational documentation with the as built hardware. The safety considerations shall be revised and updated as design and opera-tional changes dictate. The following areaa are representative example s where major safety consideration and analysis are
- required,
- a. Trade studies including risk comparisoninareas such as abort, equipment redundancy, crew egress, operational considerations, etc.
- b. Detailed design analyses, including results of failure mode effects analyses,
- c. Horizontal and vertical flight test programs.
- d. Vehicle, GSE and subsystem manufacturing, fabrication, as-sembly, checkout, maintenance, and handling.
- c. Safety aspects of integrated facility, GSE, and vehicle hard-ware operations.
f.
Compatibility between man and machine.
- g. Compatibility between vehicle s.nd ground support equipment.
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h.
Compatibility between vehicle systems and interfacing vehicles and/or cargo,
- i. Crew and vehicle operations and procedures,
- j. Interlocks to obviate personnel injury or loss of hardware.
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- k. Warning and protective devices.
l.
Compatibility of s afety factors with test and operational stresses.
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- m. Verification that changes and modifications have been incorpo-rated and are compatible prior to critical systems operations.
n.
Break-up and survival of orbital debris.
Emphasis should be given to these safetyconsiderations in relation to: mission profile, event, and environment; abort; escape; critical time periods for each subsystem necessary for crew survival; systems / subsystem interfaces; caution and warning systems to provide timely information to ground and flight personnel; testing; training; servicing; handling; fail operational / fail safe combina-tions; automatic and manual functional redundancies; switching to backup modes; failure detection and display; and public safety.
4 O rganization. The contractor shall establish a centralized safety organizational element clearly identifiable within his management structure to assure that all safety activities shall have timely planning, implementation, and effective technical safety manage-m ent.
5 Safety Coordination. The System Safety, Industrial Safety, and Test Operations Safety activities shall be fully coordinated with each other and with launch site safety activities to ensure an effec-tive and integrated total safety effort and to avoid redundant effort among technical disciplines.
- 6. Safety Audits. NASA audit teams will periodically audit the con-tractor's safety activities. The contractor shall support these audits as required. The contractor sl:all provide dataupon request which will verify internal conformance and the conformance of subcontractors to safety requirements. The contractor shall establish a schedule of audits of subcontractor safety efforts at 1 east one year in advance and shall maintaina file of audit reports available to NASA upon request.
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7 Safety Training and Certification. The contrac. tor shall provide training and certification for personnel who are to be involved in hazardous operations and activitics. The contractor shall identify positions requiring training and certification. A current status of certification shall be maintained oriented to missions, configura-tions, and locations. Protective devices and emergency equipment shall be identified and included in safety training. Hazards will be a
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brought to the attention of trainees. Proficiency demonstrations of training, to the degree feasible, are required for hazardous
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ope rations.
8 Mishap Investigation and Reporting. The contractor shall investi-gate and report accidents / incidents (including injuries topersonnel and damage to property) occurring during manufacturing, testing and ope rations. The contractor shall be prepared to provide technical assistance to NASA boards investigating mishaps which' occur within its jurisdiction.
- 9. Risk Management. The contractor shall prepare and maintain' risk management data in a composite form for management over-view and decision making purposes. This data shall be assimi-lated from each discipline and shall include risks and hazards identified by efforts such as hazard analyses, failure mode and effect analyses and human factors analyses.
I 10 Program Reviews. The contractor shall provide the means for reviewing s afety status as part of each program revie a. Risk,
management data shall be made available and/or presented at program progress reviews and milestone reviews, 11 Operational Readiness Inspections (ORI). The contractor shall perform an operational readiness inspection prior to performing any operation or test which (a) is potentially hazardous to person-nel or hardware, (b) has high risk in terms of program impor-tance, or (c) involves test hardware, facilities or effort having high dollar value. The ORI shall include a safety assessment of facilitie s, equipment, test articles, operational procedures and personnel capability.
12 Subcontractors. The contractor shall select and invoke safety re-quirements specified in thi; dicument, as appropriate, onhis sub-contractors who provide saosystems which, in either normal or emergency operational modes, may present hazards impacting system or personnel safety.
l 1D201 SYSTEM SAFETY 1
System Safety Analysis. The contractor shall establish andidentify procedures and instructions which will be used to execute all s afety analyse s.
The contractor shall perform system safety analyses assuring that:
- a. Safety is designed into the product; known hazardous conditions which cannot be eliminated through equipment design or op-erational procedures are controlled or reduced to an accept-able level. Residual hazards shall be tracked and identified to NASA.
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- b. Hazard level classifications are used to provide a continuous tracking and status of severity with the aim of reducing catastrophic and critical hazards to controlled levels within t
the constraints of risk management.
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- c. Results of previous trade studies and analyses are considered,
- d. Other related analyses, such as failure Mode and Effect Analy-ses, are considered to preclude duplication of analytical work.
i 2 System Safety Guidelines and Constraints. The contractor shall develop and establish System Safety guidelines, constraints, and requirements to guide the vehicle systems design, GSE design, 1
and operations planning. These criteria shall satisfy program-matic guidelines and constraints, system safety goals, and other top level safety objectives,' and may be extracted from existing safety guides such as the MSC 00134 Space Flight Hazards Cata-log and guidelines from previous s tudie s.
The guidelines and constraints developed specified in the applicable vehicle and GSE requirements.
3 Safety and Trade Studies. The contractor shall perform safety studies and shall develop safety inputs to support trade studies.
Specific inherently hazardous characteristics of the alternatives being considered shall be identified. The contractor shall docu-ment rationale to support the selected concept and to demonstrate that it includes the optimum safety provisions consistent with pro-gram objectives, risk management, performance, cost, and sched-ule s.
4 Hazard Analysis. The contractor shall perform a qualitative hazard analysis to identify hazards and assure their resolution.
Hazards shall be identified and classified in accordance with the hazard levels defined in the glossary of terms. The contractor shall provide for the periodic pe rformanca and refinement of hazard analysis and periodic as sessment of achieved versus specified requirements. All hazards including those resulting from failures, irrespective of subsystem or component redundancy, shall be analyzed. In addition to hazards resulting from failures, those emanating from normal or emergency equipment operations, environment, personnel error, design characteristics, and credible accidents shall also be analyzed. The contractor shall also identify and eliminate or control any failures or malfunctions that could independently or collectively present a hazard to interfacing hard-ware and assure that normal operation of a hardware item cannot degrade the safety of interfacing hardware or the total sy. item.
Early hazard analysis emphasizing design shall be the baseline of an, expanded analysis. The hazard analysis shall be updated as the program progresses, providing continuity and covering the inter-related areas of design, operations, and vehicle subsystem inte-gration.
In addition to the design and operational hazards identified, the following inputs shall be included in the hazard analysis:
- a. Credible accidents, including their definition and magni-tude.
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- b. Residual hazards (catastrophic and critical) which were not eliminated by design in previous studies,
- c. Hazards whose corrective action (s) proposed during previ-ous studies have not been accomplished and/or verified by test or analysis.
- 5. Hazard Analysis Elements. In performance of the hazard analysis, consideration shall be given to at least the following elements:
- a. Isolation of energy sources / propagation paths.
- b. Cryogenics and Propellants: their characteristics, hazard levels, and quantity / distance constraints, handling, storage, and transportation safety features, compatibility factors, etc.
- c. Proposed system environmental constraints,
- d. Use of explosive devices and their hazard constraints.
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- e. Extra /intravehicular activities.
f.
Effect of transient current, electromagnetic radiation, and ionizing radiation. Design of controls to prevent inadvertent activation of initiation circuits, h.
Crash worthiness and ditching,
- i. Documentation for safe operation and maintenance of the system.
- j. Training and certification pertaining to safe operation and maintenance of the system, k.
Egress, escape, rescue, survival, and salvage, l.
Life support requirements and their safety implications in manned systems.
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- m. Fire and explosion sources, detection, warning, and protection,
- n. Resistance to shock damage, o.
Toxicity sources: dptection and warning, p.
Man-machine relationship.
- q. System interactions,
- r. Meteoroid penetration.
s.
Docking consideration / cargo handling.
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Long term storage.
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- 6. Hazard Reduction Precedence Sequence. To eliminate or control hazards, the contractor shall use as a minimum the following sequence o? combination of items:
Design for Minimum Hazard. The major goal throughout the a.
design phase shall be to ensure inherent safety through the selection of appropriate design features as fail operational /
fail safe combinations and appropriate safety factors. Hazards shall be eliminated by design where possible. Damage control, containment and isolation of potential hazards shall be included in design considerations,
- b. Safety Devices. Known hazards which cannot be eliminated through design selection shall be reduced to an acceptable level through the use of appropriate safety devices as part of the system, subsystem, or equipment, Warning Devices. Where it is not possible to preclude the ex-c.
istence or occurrence of a known hazard, devices shall be employed for the timely detection of the condition and the generation of an adequate warning signal. Warning signals and their application shall be designed to minimize the probability of wrong signals or of improper personnel reaction to the
- signal, i
- d. Special Procedures. Where it is not possible to reduce the magnitude of an existing or potential hazard through design, or the use of safety and warning devices, specialprocedures shall be developed to counter hazardous conditions for enhancement
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of ground and flight crew safety. Precautionary notations shall be standardized.
- 7. Hazard Closure Crite ria. A hazard shall be considered closed only if:
The hazard has been eliminated by design and design accom-a.
plishment has been confirmed, or
- b. The hazard has been reduced to an acceptable level (controlled hazard) in accordance with the Hazard Reduction Precedence Sequence, and this reduction has been verified by way of a successful completion of the required testprograms, analytical studies, and/or training programs, or The hazard has been assessed and the risk has been accepted c.
by NASA.
8 Residual Hazards. Residual hazards (catastrophic and critical) shall be specifically identified to NASA. The contractor shall estab-lish a tracking system to provide the status of identified hazards and to flag catastrophic and critical hazards. Continuation of ef-fort to eliminate or reduce such hazards shall be accomplished throughout the program by maintaining awareness of new safety 2-7 q
technology or devices being developed and their application to the residual hazards. Rationale for acceptance of residual hazards shall be documented.
- 9. Human Engineering. Procedures shall be developed to assure the application of safety related human engineering principles during design, development, manufacture, test, maintenance, and opera-tion of the system or subsystem to minimize human error.
10 Interface with Other Program Functions. Safety sha11be coordinated and integrated with the other program functions to avoid. overlaps -
and conflicts among the technical disciplines, and to establish an integrated effort. This coordination shall include: the delinea-tion of responsibilities, management structure, joint analyses, reporting procedures, feedback of test data and corrective actions, use of failure mode and effects analysis, single failure point sum-maries, or other analytical techniques to identify hazards.
11 Waivers and Deviations. For proposed waivers and deviations,the contractor shall establish a means to analyze the safety impact.
- 12. Hazard Data Collection, Analysis, and Corrective Action. Using existing data systems wherever practical, a system for hazard reporting, data storage, and feedback of corrective action shall be formulated. This will involve a closed-loop system for collecting, analyzing, and recording all reported hazards that occur during the period covered by the contract.
- 13. Safety Data. Safety data provided by NASA shall be used as an aid to prevent and eliminate design and operational deficiencies.
14 Specifications and Procedures Review. Contractor generated speci-fications and procedures for manufacturing, testing, and operations shall be reviewed to assure that these activities do not negate the inherent safety of the design.
15 Safety of Government Furnished Equipment. When the overall system includes components or subsystems furnished by NASA, the contractor shall analyze the safety impact on the Shuttle sys-tens of the GFE; safety data onthe GFE shall be provided by NASA.
Where examination of these data or testing by the contractor indi-cates inconsistency of the safety of GFE with the safety require-ments of the overall system, the procuring NASAinstallation shall be promptly notified for appropriate action.
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- 16. Ground Support Equipment Safety. The contractor ' hall assure the safe design and operations of GSE. The contractor shall apply the system safety analysis approach of paragraphs 1D201 I through 15 to selected GSE related to flight and test articles containing:
a.
Pressurized vessels, tanks, lines, and similar components.
- b. Propellants, including cryogenics.
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- c. Hydraulic and/or pneumatic components,
- d. High voltages, radiation sources, and associated hazardous electrical apparatus,
- e. Subsystems containing explosives,
- f. Toxic, corrosive, and/or harmful materials or fluids.
17 Ground Handling Operations. The contractor shall assure that safe methods are implemented for ground handling and operations of his flight hardware, test hardware, and associated GSE to as-sure that the hardware is not damaged during ground handling and operations.
18 Review of Changes. When changes are proposed for equipment design or procedures, the contractor shall identify and resolve hazards that may be introduced into the system. Residual hazards shall be identified as part of the engineering change evaluation.
- 19. Postflight Evaluation. System safety shall participate in postflight reviews and a safety evaluation shall be made in cases where anomalous conditions are revealed. This safety evaluation will provide guidance in planning future missions and establishing necessary corrective action to reduce hazards.
1D202 INDUSTRIAL SAFETY The contractor shall conduct Industrial Safety activities in compliance with the NASA Procurement Regulation identified in the General Provisions schedule. Industrial Safetyincludes identification, elimina-tion, and/or control of hazards in employee and public accident pre-vention, fire prevention and protection, and transportation accident prevention at all the contractor's activities. The contractor's Indus-trial Safety / Occupational Health and Safety Plan shall consider ele-ments such as:
1 Committees.
2 Training.
3.
Ce rtification.
4 Motivation.
- 5. Inspections and audits.
6 Control of unsafe conditions.
- 7. The design, construction, and activation of facilities.
8 The operation and maintenance of facilities.
- 9. Fire prevention and protection.
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10 Handling and storage of hazardous materials.
11 Transportation 12 Hazards to the public and employees, such as pollution and waste disposal, radiation, pesticides, noise and vibration, and explosion.
- 13. Accident investigation and reporting.
- 14. Hazardous operations.
15 Personnel protective equipment.
- 16. Contingencies, emergencies, and disasters.
17 Subcontractor Industrial Safety requirements and the methods employed to insure compliance.
1D203 TEST OPERATIONS SAFETY
- 1. Margin of Safety Testing. Provisions shall be made to assure that adequate validation tests are performed on critical devices or components to determine the degree of hazard or margin of safety of design. These types of tests willbe specified in the Development and Verification requirements.
2 Testing of Critical Equipment. To protect personnel and avoid damage to test articles and facilities, the contractor shall review test plans for ground testing and flight testing of critical space flight type equipment to assure that tests are adequate to identify and assess potential flight hazards.
- 3. Safety Monitoring. Observation of designated hazardous tests /
operations shall be accomplished as necessary toinsure adherence to safety principles and compliance with safety requirements and checklists.
4 Procedure Reviews. Detailed test procedures and related docu-ments for hazardous or high cost test / operations shall be re-viewed and approved by the contractor's designated responsible safety personnel and subject to review by NASA. In the event the contractor places personnel in hyperbaric and altitude chambers i
or other similar type hazardous facilities, the procuring activity's j
safety requirements shall be met.
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CHAPTER 3: RELIABILITY 1D300 RELIABILITY MANAGEMENT The contractor shall maintain a reliability activity planned and de-veloped in conjunction with other contractor elements. Reliability functions shall be an integral part of the design and development process and shall include the evaluation of hardware reliability through analysis, review, and assessment. Timely status reporting will be utilized to facilitate control of the reliability effort. Major elements of Reliability Management are:
1 Organization. The contractor shall be responsible for the plan-ning, management, and effective execution of the reliability effort.
The accomplishment of some reliability tasks may not be the responsibility of the. reliability activity, but Reliability shall monitor and ensure that the tasks are effectively accomplished.
2 Reliability Plan
- a. The contractor shall prepare and maintain a Reliability Plan which describes how the reliability requirements willbeimple-mented and controlled. The plan shall be prepared in accord-ance with the applicable information requirements list /
information requirement description (IRL/IRD).
- b. Reliability effort at each remote test site shall be governed by a self-contained separate section of the overall Reliability Plan or by a separate plan written for each site. The contractor shall identify those sites which require a separate plan.
3.
Reliability Audits. The contractor shall conduct audits of his inter-i nal reliability activity and those activities of his suppliers. These reviews shall evaluate progress and effectiveness and shalldeter-mine the need for adjustments or changes in the reliability activ-ities. Audits shall be conducted at appropriate intervals.
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Reliability Progress Reporting. The contractor shall report on the progress of the reliability effort through periodic management meetings.
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Supplier Control The contractor shall ensure that the reliability of system ele-
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ments obtained from subcontractors and suppliers meets the reliability requirements of the overall system. This applies to items obtained from any supplier whether in the first or any subsequent tier or whether the item is obtained by an intra-company order from any element of the contractor's parent 3-1
organization. The contractor shall provide requirements, guid-l ance, and controls to ensure the adequacy of subcontractor reliability implementation. The levelof reliability requirements imposed on subcontractors and suppliers shallbe appropriately i
I tailored and identified to be consistent with those imposed on the prime contractor and shall include the state of hardware development and complexity, supplier experience, hardware unit cost, and hardware use.
b.
Where off-the-shelf hardware is anticipated, the contractor in the selection process shall examine historical data such as other contractor and program requirements and experience as well as reliability history, including failure mode and effect analysis (FMEA), maintainability, problem reporting and cor-rective action, electrical, electronic, and electromechanical (EEE) parts control, rnaterials specifications and applications, test data (certification and acceptance testing), and designdata.
The results of this examination shall be documented and addi-tional reliability controls, as appropriate, shall be applied.
6 Reliability of Government Furnished Equipment (GFE). The con-tractor shall be responsible for the identification of the reliability I
data needed on GFE. Where examination of these data or testing by i
contractor indicates inconsistency of the reliability of GFE with the reliability requirements of the overall system, NASA shall be formally and promptly notified for appropriate action.
1D301 RELIABILITY ENGINEERING j
The contractor shall accomplish the following reliability engineer-ing tasks on all flight equipment and launch essential ground support equipment (GSE), spares, and GFE as specified:
1 Reliability Design Criteria '
Reliability design criteria for each subsystem shall be developed and utilized in the design and shall serve as a checklist to ensure compliance of the design to the criteria. The contractor's re-l liability effort shall include a system for the review and con-l currence of design specifications and changes. The review shall ensure that the set of specifications covers all items of hard-l ware and contains applicable reliability design criteria and re-quirements.
2 Trade Studies. The reliability effort shall includet participation in design trades and shall utilize reliability nurrerical estimates as appropriate.
3 Failure Mode and Effect Analysis (FMEA) and Critical Items List (CIL). The contractor shall establish a system for the preparation, maintenance and control of FMEA's and CIL's.
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a.
The contracto r shall prepare design FMEA's at the lowest level of system definition required to support the potential uses ( e.g., testing, failure reporting and corrective action, preparation of mandatory inspection points, etc.). FMEA's will be performed to the " black box" level and within the
" black box" to pursue all critical functions. The identification of failure modes to the piece part level will be accomplished when these failure modes are criticality 1 or 2. The FMEA shall include an integration of all flight hardware, including GFE, and launch essential GSE. The contractor effort shall including the necessary interface with the GFE contractors to ensure compatibility so that the integration canbe accomplished effectively.
- b. Based on results of the FMEA's, a CIL shall be prepared con-sisting of a single failure point summary (SFPS) and a sum-mary of redundant elements in life or mission essential components where:
(1) the redundant elements are not capable of checkout during the normal mission turnaround sequence; c :-
(2) loss of a redundant element is not readily detectable by the flight or ground crew; or (3) all redudant elements can be lost by a single credible cause or event such as contamination or explosion.
c.
Equipment appearing on the CIL will be given special attention in establishing hardware specifications and qualification re-quirements; in manufacturing, inspection and test planning; and in the formulation of operating and maintenance procedures and mission rules.
4 Reliability-Maintainability Interface
- a. The contractor shall provide reliability engineering imputs and participation in establishing maintainability criteria and plans to obtain maximum benefit from both design disciplines. Inter-facing reliability tasks such as FMEA and redundancy studies shall be coordinated closely with corresponding maintainability trade-offs.
- b. The contractor shall identify limited life items, including GFE specified by NASA, which require control from equipment date of manufacture throughout operational use, including storage.
Provisions will be made for replacement or refurbishment of hardware after a specified age or operating time / cycle.
The contractor shall report to NASA the status of. limited life items and waivers on limited life items.
5 Design Peview and Readiness Review. The contractor's reliability activit~ s shall include support of internal and supplier design reviews at the system, subsystem, and componentlevels and NASA 3-3
4 design and readiness reviews, This activity shallinclude an assur-ance function for compliance of the design to the design criteria defined for the system, subsystem, and component levels. Each engineering change package shall contain a reliability assessment of the effect of the proposed change.
- 6. Problem Reporting and Corrective Action. The contractor shall 4
provide a closed-loop system for the reporting of all problems (failures and unsatisfactory condition reports) and the establish-ment of corrective action for all problems concerning flight, test, simulator, and training hardware where that hardware is repre-s entative of flight hardware, GSE, applicable GFE, and spare hardware. The contractor shall be responsible for ensuring that problem reporting and corrective action systems of suppliers will meet the requirements of this section.
- a. Problem Reporting. Reporting of problems shall be in accord-ance with the applicable IRL/IRD.
b.
Problem Analysis. An analysis of each problem reported to NASA shall be performed to deterrnine the cause of the problem and to implement adequate measures to prevent its recur-rence. Primary emphasis shall be placed on hardware teardown analysis; however, where the cause of the problem is under-stood or where sufficient prior analysis experience has been obtained, additional hardware teardown for analysis may not be requir ed.
c.
Problem Resolution. The contractor shall resolve each prob-lem by one of two methods: closeout or explanation. The con-tractor shall direct all efforts toward closing a problem in lieu of an explanation, and in no case shallthe contractor attempt to.
" explain" a problem until it becomes impracticable to close the problem.
- d. Problem Status. The contractor shall maintain a status on all open problems. The method (s) employed by the contractor in maintaining the status of problems shall be compatible to the contractor's needs as well as those of NASA in responding to requests for information. The contractor shall submit to NASA a listing of all open problems in accordance with the applicable IRL/IRD.
7 Reporting and Resolving NASA Part s and Materials Problems (ALERTS). Problems with parts, materials, or equipment which are of mutual concern to NASA and associated contractors are reported by utilizing the NASA ALERT system (NASA Form 863).
The contractor shall establish a systematic approach to evaluate and respond to all NASA ALERTS and to investigate, resolve, and document parts and materials problems. Previously published ALERTS will be reviewed to assure that lots, batches, or other groupings of hardware noted as suspectinthe ALERT are not used.
A summary of previously published ALERTS will be provided by NASA.
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- a. Investigation. Upon receipt of a problem ALERT, the contrac-tor will initiate an immediate investigation to determine the use significance of the problem item identified by the ALERT in its in-house program and in that of its subcontractors and supplie rs,
- b. Resolution. Subsequent to the start of acceptance tests when investigation discloses known or suspected usage of the prob.
lem item identified in the problem ALERT, a problem report will be issued against equipment having such usage. The reports will be prepared, resolved, and closed in conformance to the method defined in the Reliability Plan.
1 c.
Response. The contractor shall provide a documented response each ALERT investigation and resolution to NASA in ac-on cordance with the applicable IRL/IRD.
- d. Contractor-Initiated ALERTS. When the contractor encounters a sigmficant problem with a part or material which may ad-versely affect equipment, the contractor sha11 initiate an ALERT and submit it to the NASA ALERT coordinator. The contractor shall not release an ALERT on equipment without prior NASA approval.
8 Electrical, Elect ronic, and Electromechanical (EEE) Parts and Mechanical Parts Control
- a. Gene ral. The contractor shall implement a system for con-trolling the s election, reduction in number of types, speci-fication, application review, analyzing failures, stocking and handling methods, installation procedures, and establishing reliability requirements for EEE and mechanical parts to be used in contract and off-the-shelf hardware.
b.
EEE Parts Selection. The contractor and suppliers sha11 select EEE parts for the contract hardware on the basis of suitability for their application (s) and proven qualification of each to the requirements of its specification. Wherever practicable, items selected shall be already qualified to pertinent specifications, selection shall minimize the number of styles and generic types, and consideration shall be given to in'dustry and Government preferred parts lists (e.g., MSFC document 85M03936). When selecting items previously qualified, the contractor sha11 devote particular attention to the currentness of data, applicability of basis of qualification, and adequacy of specifications. The re-sults of the selection effort will determine requirements for additional qualification testing and will be the basis for the EEE parts list for the systern. (See paragraph 1D301-8d.) The con-tractor is fully responsible for the satisfactory performance of each part regardles s of the source from which the part selected or who wrote or approved the controlling docu-was mentation.
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c.
EEE Parts Specifications (1) Each EEE part shall be controlled by a specification (or combination of specifications) which delineates as a mini-mum: complete identification of the part; physical, environ-mental, and performance requirements; reliability require-ments including inspections and tests for qualification, acceptance, and lot sampling where required; explicit requirements to be satisfied in accepting parts for use in the contract hardware including 100 percent screen and burn-in; packaging, storage, and handling requirments; traceability requirement; and data retention and submittal requir ement s.
(2) Where a combination of specifications is used collectively to provide all of the above requirements for a single part type, the detail specification (slash sheet, specification con-trol drawing, etc.) for that part type shall provide detailed cross-reference to all other applicable specifications.
(3) Each specification shall be identified by a unique number, and all specifications shall be subject to a formal system of change control.
(4) All EEE parts specifications shall be available for NASA review upon request, d.
EEE Parts Qualification (1) Qualification of EEE parts shall be at the part level to the requirements of the applicable specifications. Where ade-quate qualification data are not available (as determined jointly by the contractor and NASA), the contractor shall be responsible for the development and conduct of qualification tests on pa rts to determine their adequacy in meeting specification r equir ement s and for the development of criteria to be used in acceptance testing. The contractor shall prepare test plans for those parts which it will subject to qualification testing.
(2) Requalification of parts shall be conducted as necessary to ensure continued control over design, materials, manu-facturing processes, and quality cont rols after initial qualification.
(3) Qualification test plans and test reports shall be in accord-ance with the applicable IRL/IRD. In the event a part is used which deviates from this requirement, the contractor will submit a waiver request for the deviation.
(4) The contractor shall maintain a data file which identifies the basis and substantiates the status of qualification for each EEE part type used on the project. The file for each part type shall:
(a) Completely identify the part by generic part type and na m e, controlling specification name and number, com-mon designation (closest commercial equivalent), and manufacturer's name and part number.
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(b) Contain a summary of and provide complete cross-reference to all existing data used to substantiate the qualification of the part to the controlling specification.
When the basis of qualification is similar to an already qualified part, complete identification and supporting data for the similar part shall be included together with the analysis that establishes similarity,
- e. EEE Parts List and Where-Used Parts Lists. The contractor and suppliers shall prepare and maintain a project EEE parts list and composite where-used parts list will be prepared in accordance with the applicable IRL/IRD.
- f. EEE Parts Application Review. The contractor (or supplier, if appropriate) shall conduct thorough parts application reviews on the design of each component (black box) at appropriate milestones during its design and development. The results of these reviews will be an input to the design reviews. (See para-graph 1D301-5.) The application of each part shall be examined in light of its rated capabilities in comparison to the design requirements of that application and conformance to the estab-lished derating criteria. The derating criteria shall, as a mini-mum, require a 25 percent margin between a11 upper and lower worst-case application stress levels and the corresponding specification stress level for which the part has been qualified.
Consideration shall be given to anticipated life requirements, functional and environmental usage stresses, and historic and current failure experience (i.e., results of analyses of parts failures which have occurred in higher level assemblies on the same system or other projects). Special attention shall be given to any parts used which are not selected from the project parts list, and the review output documentation sha11 include or refer to justification for each such usage. The contractor shall take immediate action to correct identified deficiencies.
g.
EEE Parts Handling and Traceability (1) The contracto r shall specify minimum requirements for control of storage, stocking, and installation procedures for parts. These controls shall prevent use of parts which may be in a questionable condition and prevent degradation of parts due to environments or faulty manufacturing or assembly techniques.
(2) The contractor shall assure that backward traceability data can be provided for all EEE parts. (See paragraph 1D502.)
Provisions shall be made to record and retrieve information relating to the specific tests performed, test results, and each lot of parts. Identification of the part processes on manufacturer's production, assembly, or test lot shall be available for each part installed in deliverable end items including qualification and test articles.
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h.
EEE Parts Problem Reporting and Corrective Actihn. The con-i tractor shall investigate the cause of each part failure and determine remedial and preventive action. The significance of the failure as related to like parts or materials used elsewhere in the system and the possibility of the occurrence of additional failures shall be determined and documented as part of the problem disposition in accordance with paragraph 1D301 6, Problem Reporting and Corrective Action.
- i. EEE Parts Deviations and Substitutions. The contractor shall establish and maintain an adequate system to monitor and con.
trol the use of deviated and substituted parts in contractor, subcontractor, and supplier equipment at all levels of procure-ment, test, and fabricatiorm The system shall provide for the prompt identification, reporting, r eview, and approval /
disapproval disposition of the deviated or substituted parts.
The provisions of this paragraph will be invoked when EEE parts do not conform to paragraph 1D301-8c, Parts Specifi-cation, and paragraph 1D301-8d, EEE Parts Qualification.
(See Glossary of Terms for definitions) Subsequent to the CDR,-
all requests for EEE part changes, deviations, or substitutions shall be submitted to NASA for approval,
- j. EEE Parts Control for Off-the-shelf Equipment (1) EEE parts used in off-the-shelf equipment shall conform to the requirements of paragraphs ID301-8c and 8d. A where-used parts list in accordance with paragraph ID301-8c is required. A parts application review in accordance with paragraph ID301-8f must be accomplished and must assess the adequacy of each part in each application and assure compliance with any applicable NASA restrictionon specific parts usage or application. The requirements of paragraph ID301-8g apply to any new manufacture of equipment to an existing design.
(2) Problem reporting ard corrective action in accordance with paragraph ID301-8h na control of substitutions and devi-ations in accordance with paragraph 1D 301-8iare required.
k.
Mechanical Parts. MIL-STD 143, " Standards and Specifications, Order of Precedence for the Selection of," shall apply in select-ing specifications for standard mechanical parts. Rationale for the s election of company specifications and standards over existing higher order of precedent standards and specifications shall be made available to the procuring activity upon request.
This rationale shall include an identification of each higher order of precedent specification or standard-examined and state why each was unacceptable.
- 9. Materials Specifications and Application Reviews a.
Materials Specifications. The contractor shall review design specifications to determine compliance with all required mate-rials specifications. These specifications shall constitute the basis for description and control of all materials to be used in 3-8 I
i
l the contract hardware. Where adequate specifications do not exist (as determined jointly by the contractor and NASA), the contractor shall make appropriate recommendations to NASA.
b.
Materials Application Reviews. The contractor shall review all materials applications for compliance withflammability and material specifications. The contractor (or supplier, if appro-priate) shall conduct thorough materials application reviews on the design of each component (black box) at appropriate milestones during its design and development. Consideration shall be given to anticipated life requirements, functional and environmental usage stresses, and historic and current failure 1
experience (i.e.,
results of analysis of materials failures which have occurred in higher level assemblies on the same system or project). Special attention shall be given to the con-tinuous review and assessment of flammability and off-gassing properties of materials. This shall include, but not be limited to, material usage, status, test, evaluation, substitution, and verification. The results of these reviews will be an input to the design reviews. (See paragraph 1D301-5, Design Review and Readiness Review.)
1D302 TESTING The contractor shall participate in the conduct of the certification and acceptance test program as follows:
1 Certification. The contractor shall monitor and support the cer-tification program established to demonstrate that the design of flight hardware is capable of performing its intended mission, j
The contractor shall assure that adequate documentation is main-i tained to substantiate and track activities in meeting certification requirements imposed by contract.
j l
2 Acceptance Testing. The contractor shall review all acceptance i
test requirements to assure that they are adequate for perform-
~
ance verification and to detect manufacturing defects.
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CHAPTER 4: MAINTAINABILITY ASSURANCE 1D400 MANAGEMENT The Contractor shall provide this design assurance discipline in con-junction with reliability during all program phases with the major effort concentrated in the design phase. The Contractor's maintain-ability program shall consider all pertinent operations and missions requirements and be closely integrated with the maintenance engi-neering service and support function. The Contractor shall prepare a Maintainability Plan which describes how the program will be accomplished, including necessary participation of subcontractors and suppliers. The plan shall be prepared and submitted in accordance with the applicable IRL/IRD.
1D401 PROGRAM ELEMENTS The maintainability program shall include the elements described below as a rainimum.
1.
Maintainability Parameters. Establish measurable parameters such as mean time to repair, fault detection / isolation capa-bility and maintenance manhours per turnaround considering turnaround / reaction time requirements, limited life items (see par. ID401-4a) maintenance resources, and other factors.
- 2. Maintainability Allocation. Budget parameters to syst em/sub-system / equipment and establish criteria to meet targets.
3.
Maintainability Analysis. Evaluate proposed designs and provide maintainability predictions in a timely manner so as to influence designs without costly changes. Conduct trade-off studies consider-ing maintainability versus such element s as cost, weight and reliability. Provide inputs to design and to logistics and mainte-nance planning.
4.
Design Reviews. Conduct in-house and supplier reviews and sup-plier reviews and support NASA reviews to assure the maintain-ability features of the developing deaigns are optimized.
5.
Maintainability Data. As maintainability data on hardware become available from supplier and in-house developments and operations, collect, analyze and compare with established maintainability targets. Feedback to design for corrective action the critical maintainability areas disclosed.
6 Verification and Demonstration. Through analyses and practical demonstrations on mock-ups and early flight hardware, verify the achievement of design maintainability requirements.
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7.
Maintenance Data. When operational experience beco:nes available, these data shall be collected and analyzed and compared to allo-
)
cations and predictions. Where discrepancies exist, corrective action shall be initiated and the results reported to NASA.
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s 4
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CHAPTER S: QUALITY ASSURANCE 1D500 MANAGEMENT AND PLANNING
- 1. Planning. The contractor shall maintain an effective and timely quality assurance activity planned and developed in conjunction with all other contractor's functions necessary to satisfy the con-tract requirements. The activity shall:
Demonstrate recognition of the quality aspects of the contract a.
and an organized approach to achieve them,
- b. Ensure that quality requirements are implemented and satis-fied throughout all phases of contract performance, including preliminary and engineering design, development, fabrication, processing, a s s embly, inspection, test, checkout, packaging, shipping, storage, maintenance, field use, flight preparations,'
flight operations, and post-flight analysis, as applicable.
- c. Ensure that quality aspects are fully included in all designs and are continuously maintained in the fabricated articles and during operations.
d.
Provide for the detection, documentation, and analysis of actual and potential deficiencies, system incompatibilities, marginal quality, and trends or conditions which could result in unsatis-factory quality.
Provide timely, effective documented remedial and preventive e.
action.
2 Organization. The contractor shall ensure that the effectiveness of quality functions and the ability of assigned personnel to objec-tively assess,' document, and report findings is not hampered by other considerations (such as the overt influence of engineering changes, rework, or rescheduling) during aliphases of the contract work. The contractor shall designate one individual who shall have the i
responsibility and authority for directing and managing the quality a ctivity. He shall have direct, unimpeded access to the management level having full responsibility for the contract work 4
and shall report regularly to higher management on the status and aMuacy of the quality activities.
3 Quality Plan. The contractor shall prepare, maintain, and imple-ment a Quality Plan which describes how he will ensure com-pliance with the requirements set forth herein. The plan shall be submitted as specified in the applicable IRL/IRD.
The plan content shall be readily identifiable with each cited requirement 5-1
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and shall cover all quality activities for the contract. Contractor policies and procedures which implement these requirements shall be identified. The contractor shall use existing policies and pro-cedures to the maximum extent. New procedures should only be developed for the un!que requirements of a cost-effective system, such as the use of deaignees (see par ID505-9) or certification of suppliers' quality systems. Procedures which define Government involvement shall be reviewed and approved by NASA. New or existing policies and procedures which contain no Government in-volvement shall be available for NASA review. Changes to the plan shall be in accordance with instructions specified in applicable IRL/IRD. The plan shall serve as the master planning and control document. Separate Quality Plans, or a planwith separate sections shall be prepared for the contractor's activities atthe plant site and at each remote test site,
- 4. Quality Controls. The contractor shall develop effective manage-ment control of his quality effort. The contractor shall identify how its quality tasks will be implemented for both contractor and supplier hardware within the scope of the basic quality tasks. The quality requirements implemented shall be tailored to include the state-of-hardware development, contractor experience, hardware unit cost, complexity, and hardware use.
- 5. Nondest ructive Evaluation. The contractor shall integrate the definition, assessment, validation, and application, including se-quence of operation, of NDE (nondestructive evaluation) methods, to meet design, development, production, and test requirements of the Shuttle program. Provisions for NDE shall be optimized for the operational requirements. For critical components and struc-tures, quantitative accept / reject criteria shall be established to enable selection of validated NDE methods capable of detecting inci ient flaws and variations in material properties. When as-9 sessment of NDE capability indicates the desired capability cannot be obtained utilizing " state-of-the-art" NDE, alternate design or fabrication techniques shall be considered. If these changes cannot satisfy the desired evaluation capability, the contractor will per-form additional validation tests or identify the supporting research and technology needed to either develop new or extend existing NDE methods.
- 6. Management Assessment Data. The contractor shall present the quality status at periodic meetings with NASA. The meetings should cover significant accomplishments, potential management and hardware problems, recommendations, summary of remedial and preventive actions, quality costs, and presentation of pertinent data. Pertinent data shall include scrap rates, frequencies of re-pairs and trend charts by end item, discrepancies which indicate.
totals as well as their relation to special processes (e.g., wiring, contamination, etc.). The cont racto r's system shall allow the identification of costs of both prevention and correction of non.
conforming supplies (e.g.,
labor and material, when available, involved in material spoilage caused by defective work, correc-tion of defective work, and for quality control exercised by the 5-2
contractor at subcontractors' or vendors' facilities). These data shall be included for selected subcontractors and suppliers. The data shall be submitted in accordance with the applicable IRL/
IRD.
7 Training Planning. The contractor shall develop, maintain, and imple-a.
ment necessary quality training. Training activities shall be documented and shall provide for:
(1) Excellence of workmanship and personnel skills.
(2) Careful and safe operations.
(3) Maintenance and improvement, where necessary, of article and material quality.
The training for critical processes (refer to the Glossary of Terms) shall include, as applicable, adhesive and resin applica-tion, welding, brazing, soldering, electrical connector operations, contamination control operations, and nondestructive testing evM-uations. The contractor shall utilize the list of critical processes (refer to paragraph 1D504-4C) to develop training requirements..
- b. Certification of Personnel. Contractor personnel controlling critical processes and personnel performing critical opera-tions shall be certified. Certification shall include satisfactory completion of a NASA approved writt' i examination and/or a performance demonstration which m be repeated by NASA, or its designat,ed representative, ti terify the adequacy of such certification. Personnel certified by the contractor shall be given a card, badge, or similar evidence of certification to be carried on their person while performing their duties.
- c. R ec e rtification of Pe r s onnel. Contractor personnel shall be recertified based on contractor or Government observation of unsatisfactory quality of articles or services; changes in tech-niques, parameters, or required skills; or interruption of work period as established for the process or operation involved.
Rec ertification shall require retesting of the individual to the testing procedure to demonstrate continuing proficiency.
Pers:,ns failing the retest shall not be permitted to perform these processes or operations until provided with additional training and required proficiency has been Bemonstrated.
- d. Secords. Records shall be maintained of the training, testing, a ~1 certyication status of personnel.
- 8. Qualit. f rogram Audits
- a. G er. t. al. The contractor shall conduct audits of personnel, prot etures, and operations which implement the quality pro-g ra r. s. Each audit shall be performed by a team of contractor 5-3 i
personnel familiar with all written procedures and standards applicable to the operation or work areas being audited and shall include personnel not having specific line responsibilities in those areas. Each audit shall include examination of all operations and documentation, evaluation of actual operations as compared with established requirements, recommendations for remedial and preventive action, and followup to assess results of recommendations. Audits shall include examination.
of articles and materials to verify the effectiveness of the contractor's efforts,
- b. Audit Schedule. Random unscheduled audits shall be performed in order to effectively assess existing conditions and opera-tions. Audits are to be conducted on a random basis, but pro-l visions shall exist to ensure that each quality area is audited.
l c.
Audit Reports. The results of audits in each area shall be documented in a report to contractor higher management with appropriate recommendations for correction of deficiencies.
Management action shall be taken to ensure effective cor-rection of the reported deficiencies. Followup reviews shall be made to ensure that required corrections have been im-plement ed.
1D501 DESIGN AND DEVELOPMENT CONTROLS 1
Technical Documents a.
The contractor shall establish, document, and ensure com-pliance with design control requirements and quality criteria during all phases of contract work. The contractor shall ensure i
l enclusion of quality characteristics and design criteria nec-essary for procurement, fabrication (including assembly), in-spection and test operations, and post-flight operations (includ-ing inspection, test, refurbishment, and prelaunch checkout),
as applicable in specifications, procedures, drawings, and fabrication and planning documents.
- b. The contractor shall utilize a system which identifies hard-ware characteristics requiring verification. This identification should be based on the use of the hardware involved and shall be utilized in developing quality inspection and test surveillance planning, as an input to the development of Inspection Points, and in the development of quality criteria, l
workmanship and inspection standa rds, and inspection pro-l cedures.
- c. Contractor quality assurance personnel shall conduct timely.
review of technical documents that affect quality and changes thereto. Reviews shall ensure that all necessary information has been included and that requirements are clear and un.
ambiguous. The reviews shall be documented and action shall be taken to ensure correction of deficiencies. Thue reviews shall 5-4
i l
l also be an integral part of the quality planning function to en-i sure timelyplanning of quality activities andfacilities associated with subsequent procurement, fabrication, assembly, inspec-tion, testing, delivery, post-flight inspections and tests, and refurbishment activities.
2 Quality Support to Design Reviews The contractor's quality activity shall include participation in design reviews to ensure that designs permit and facilitate producibility, r e p e a t a b ili t y, inspectability, refurbishability/
maintainability and that related quality considerations are well defined. Quality design criteria shall be developed and utilized in the design and shall serve as a checklist during the design reviewa to assure compliance with the criteria. Participation in review activities shall be documented to provide a historical record of quality performance and subsequent concurrence with design development as noted below:
Contractor Internal Design Reviews. In implementing quality a.
r equir ements, the contractor's quality activity shall assure that the program documentation (drawings, specifications, technical documents) includes, as a minimum:
(1) Identification and data retrieval requirements (par 1D502);
(2) Identification of critical hardware characteristics neces-sary for procurement and fabrication (including assembly, inspection, and test operations);
(3) Inspection and test criteria (including specific NuEmethods, test equipment, environmental conditions, and sample size, as applicable);
(4) Performance and/or tolerance limits; (5) Applicable specifications for contamination control; (6) Applicable process specifications, standards, and pro-cedures; (7) Limited life items; and (8) Acceptance / rejection criteria.
'I he contractor's quality activity shall participate in review of selected program 1
documentation prior to submittal to NASA and ensure the following:
(1) Repeatability and inspectability of the selected design ap-proach by determining the special inspection and testing tools, equipment, and facilities required; 5-5
o (2) Characteristics which influence quality are within inspec-tion " state-of-the-art" capabilities; (3) Criteria to judge conformance to these characteristics have -
been established; (4) Quality controls at interfaces are noted adequately in the interface control documents; (5) Process specifications and quality controls have been adequately defined; (6) Design criteria and procedural standards have been con-sidered; and (7) Acceptance test specifications contain adequate acceptance /
rejection criteria.
- c. Acceptance Reviews. The contractor shall ensure that the fol-,
lowing are accomplished in support of the acceptance reviews:
(1) Evaluation of test and checkout operations and results with discussion of anomalies encountered, failure history, and remedial and preventive actions; status of all open tests with an identification of those that constrain further ac-tivities, such as flight mission.
(2) Identification of waivers and deviations to specifi. cations and verify basis for approval.
(3) Status of limited life components and their remaining 1ife.
(4) Identification of shortages, open work items, and related corrective actions.
(5) Status of open work items (to be accomplished).
(6) Development of a form DD250 indicating shortages and de-ficiencies which must be resolved prior to further activ-ities, such as flight readiness.
(7) Verification that departures from specifications and draw-ing requirements have been processed in accordance with paragraph 1D506 (8) Verification that all data packages and support manuals for the operation, checkout, and maintenance of the end-item are complete, compatible and accompanying the hardware, and that all shipping requirements of this document have been met.
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Change Control The contractor shall be responsible for control of quality gen-a.
erated documents and changes thereto. Documents affecting quality shall be distributed to the proper control locations at the proper times and obsolete documents removed from the system. All engineering changes shall be reviewed to deter-mine quality impact. Necessary interfaces with program man-agement, data management, and configuration control functions shall be provided in order to define and facilitate reporting directly to top management any quality impact due to program documentation changes.
- b. The contractor shall be responsible for coordination of engi-neering changes affecting the quality activity between both contractor and subcontractor quality activities to ensure proper j
and timely assessment of any quality impact.
The contractor shall verify that the effectivity point of docu-c.
ments and changes which affect materials, fabrication or qual-ity is clearly identified. The contractor shall verify that changes are accomplished on the affected articles or materials at the authorized point; changed articles are appropriately 3
marked or identified; and associated documents are revised i
accordingly. Provisions shall be made for inspection and test of changed articles or materials.
1D502 IDENTIFICATION AND DATA RETRIEVAL 1
General. The contractor shall develop and maintain a systematic technique of documented identification and data retrieval for articles and materials to provide:
- a. Identification to which procurement, fabrication, processing, inspection, test, and operating records can be related, and
- b. Means for locating articles and materials.
~
The contractor technique shall be developed in conjunction with other contractor systems, such as engineering documentation control, configuration management and logistics management.
Common identification numbers and procedures shall be used among all systems. The data requirements may be implemented by the use of a manual data and record system, or a mechanized system may be used in lieu of, or in support of, a manual system.
2 Identification and Data Retrieval Requirements. Selected items based on design complexity, application, performance characteris-tics, manufacturing, processing or environmental conditions, and limited life sensitivity shall be subjected to identification and data retrieval requirements. These items (including components and parts along with connecting lines and/or tubes) shall have detailed identification to their origin,
- e. g., manufacturer, materials, manufacturing date, purchased lot, inspection or test data, or 5-7 l
other pertinent information. Identification and data retrieval re-quirements shall be established for electronic, electrical, and electromechanical parts which will provide the capability of tracing backwards from fabricated hardware to the records re-quired in par.1D502-5. Provisions shall be made to record and retrieve information relating to the specific test performed, test results, and processes on each lot of parts. Equipment with identification and data retrieval requirements shall automatically require identification and data retrieval through all higher levels of assembly.
- 3. Identification Methods. Each article and material shall be identi-fied by a unique part or type number. Where control of individual articles, lots of articles, or materials is required, one or more of the following detailed identification methods shall be used, as applicable:
- a. A te Codes. Date codes indicating date of manufacture to identify articles or materials made by a continuous and con-trolled process and those which are subject to variations on -
degradation with age.
b.
Lot Numbers. Lot numbers to identify articles or materials produced in homogenous groups and where unique data are not required to be related to individual items. Heat, billet, or l
batch numbert are included in this category.
- c. Serial Numbers. Serial numbers to identify individual mate-rials or articles for which unique data are to be maintained or when other reasons exist for individual control.
d.
Other Identification. Other identification methods, such as paint dots in lieu of or in addition to the methods specified herein, upon approval of the designated Government quality repres entative.
4.
Docuinentation. Method and location of part or type numbers and detailed identification on articles and naaterials shall be indicated in technical documents.
~
- 5. Identification Cont rol. Controls shall be established to ensure that detailed identification numbers for individual articles and materials or lots thereof are assigned in a consecutive manner.
Records for articles and materials shall indicate applicable part or type numbers and associated detailed identification. This shall provide the capability of tracing backward to the material from which fabrication originated and to determine the location of the like articles or materials within a level of process or assembly.
Serial or lot numbers of scrapped articles or materials shall not be used for other similar articles or materials. Temporarily in-stalled items shall be clearly identified to permit easy location and rapid removal after use.
- 6. Record Retrieval. Contractor identification systems shall ensure that article and material procurement, fabrication, processing.
l inspection, and test records are related to the applicable articles 5-8
and materials. It shall be organized so that these records and the related articles and materials may be located and retrieved in the event verification of, or removal of, articles and materials be-comes necessary. If required, complete data and record retrieval and analysis should be accomplished within a reasonable period based on the urgency of the problem.
7 Retention of Records. Records of articles and materials which have been designated for identification and data retrieval shall be retained in a safe, accessible location by the contractor for the period specified in the contract, unless released prior to that time by contractual authorization. The contractor shall also invoke this same requirement on his subcontractors and suppliers. The prime contractor shall be responsible for assuring that applicable rec-ords are not destroyed, unles s authorized by the contracting offic er.
1D503 PROCUREMENT 1
Procurement Controls. The contractor shall assure the adequacy and quality of all contractor-purchased articles, materials, and s ervic es. The contractor shall plan, implement, and maintain procurement quality activity to ensure tirr.edy and adequate inte-gration with all other elements of his organization (design, pro-curement, etc.) having responsibility for control and performance of subcontractor / suppliers (hereinafter designated procurement sources). The responsibility for ensuring overall planning and implementation of quality assurance functions at all procurement shall be assigned to one clearly identified group within sources the contractor's quality organization. The activity shall provide for long-range and detailed planning, total visibility of all pro-curement quality activities, functional integration within the con-tractor organization, and effective performance at all levels of procurement, including subtier sources and other divisions or subsidiaries of the cont ractor. Functional responsibility shall include, but not be limited to, the following:
- a. Participate in selection of qualified procurement sources, b.
Develop quality requirements for each procurement source.
c.
R eview and/or approve selected procurement documents in-cluding, as a minimum, flight hardware and launch essential GSE.
- d. Ensure that procurement documents refer to specific items requiring identification and data retrieval.
- e. Provide technical assistance and training to procurement sources when necessary to achieve desired quality levels.
f.
Approve procurement source quality and/or inspection systems.
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g.
Provide resident or itinerant quality control representatives as required, h.
Monitor, survey, and assess procurement source quality per-formance including staffing practices.
2 Selection of Contractor Procurement Sources. Contractor quality personnel shall participate in the s election of procurement sources. The contractor's evaluation and selection shall be based on one of the following:
- a. The procurement source shall have a previous and continuing record of supplying quality articles, materials, or services of the type being procured. This record shall be supported by qualitative and quantitative documentation.
- b. A pre-award survey of the procurement source facility and quality system shall be conducted in accordance with docu-mented contractor procedures to determine if the procurement source is capable of satisfying procurement quality require- -
ments. The results of pre-award surveys shall be documented and maintained on file by the contractor.
c.
When articles or materials are not fabricated specifically for contracts or subcontracts issued under NASA contracts, a pre-award survey of the source is not required. In such cases, thorough inspection of the articles and materials shall be a
performed in accordance with technical documents.
- a. R eview. Selected procurement documents that are issued at contractor plant sites and facilities, including other divisions or subsidiaries of the contractor, shall be reviewed by quality personnel prior to release for adequacy of quality require-m ents. Such reviews shall be documented and shall include determination that:
(1) Procurement sources have been selected in accordance with paragraph ID503-2, and l
(2) Applicable provisions of paragraph 1D503-3b have been properly cited.
i
- b. Contents. Procurement documents shall c'ontain provisions for the following:
(1) Procurement Source Quality Activity. Each procurement source and its subtier sources shall be required to comply with one of the following:
(a) Subcontracts for procurement of systems, subsystems, and related services shall invoke this document or ap-plicable portions thereof.
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(b) All other suppliers except those of off-the-shelf hard-ware shall be required to follow the applicable pro-visiens of this section and/or NASA publication NHB 5 300.4(1 C). The contracto r, in complying with these requirements, may use his existing procurement re-quirements document (s) as identified in the Quality Plan. Approval by NASA shall be required prior to implementation. For off-the-shelf hardware suppliers, historical data shall be examined and assessed to deter-mine the appropriate quality controls to be applied. The requirements for each procurement shall be tailored to include only the necessary requirements basedprimarily on the state-of-the-hardware development, the contrac-tot experience, hardware unit cost, and the use of the part, component, subsystem, or system.
(2) Basic Technical R equirements. Procurement documents shall specify or refer to technical requirements for arti-cles, materials, or services to be provided by a procure-ment source. Applicable revisions shall also be indicated and documents provided.
(3) Detailed Quality R equirement s.
The following detailed quality requirements, as necessary, shall be additionally included or technical documents containing these re-quirements shall be referred to. Applicable revisions of referenced documents shall be indicated and documents provided as necessary to the procurement source.
(a) Changes. The procurement source shall be required to notify the contractor of any proposed changes in design, fabrication methods, or processes approved by the con-tractor, including changes which may affect the quality or intended end-use of the item, and obtain written ap-proval of the change from the contractor before making the change. Changed articles shall be identified differ-ently from previous articles. When a proprietary item is procured by the contractor, the procurement source shall be required to notify the contractor of changes in its design, fabrication methods or processes, (b) Purchased Raw Materials. Purchased raw materials i
shall be accompanied with chemical and/or physical test results.
(c) Raw Materials Used in Purchased Articles. Tests per-formed on specimens or detailed analyses of procure-ment source acceptance test results on all raw materials that are required to satisfy specification requirements and which are employed in the fabrication of articles purchased on this subcontract or purchase order shall be made available to the contractor upon request.
(d) Preservation, Packaging,
- Packing, and Shipping.
Requirements for preservation, packaging, packing, and shipping of articles and materials shall be specified or referenced.
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(e) Age Control and Life Limited Products. Records for articles and materials having definite characteristics of quality degradation or drift with age and/or use shall indicate the date and test time or cycle at which useful life was initiated, the life or cycles used, and the date and test time or cycle at which useful life will be ex-pended. When appropriate, specify that the articles and materials exhibit similar information. The procurement.
source shall ensure removal or rework of such articles and materials are required.
(f) Identification and Data Retrieval. Identification and data retrieval requirements shall be specified.
(g) Inspection and Test Characteristics. Characteristics to be subjected te inspections or tests by the procurement source shall be specified.
(h) Inspection and Test Records _ Inspection and test records to be maintained by the procurement source to provide evidence of inspections and tests shall be clearly speci.
fied. Records to be provided to the contractor or his source inspection personnel shall be specified.
(i) Resubmission of Nonconforming Articles or Materials.
(
' Nonconforming articles and materials returned to the procurement source by the contractor and subsequently resubmitted by the procurement source to the contrac-tor shall bear adequate identification of such resub-mission either on the article or material or on pro-curement source records. Reference shall be made to the contractor's nonconformance document and evidence provided that causes for nonconformances have been corrected and actions taken to preclude recurrence.
(j) Contractor Quality Assurance Activity at Source. When contracto r quality assurance activity is required at source, the procurement document shall so indicate.
(k) GSI (Government Source Inspection). When the Govern-m ent elects to perform inspection at a procurement source, the following statement shall be included in the l
procurement document:
"All work on this order is subject to inspection and test by the Government at any time and place.
The Governmer}t quality representative who has been delegated NASA quality assurance functions on this procurement.shall be notified immediately upon receipt of this order. The Government rep-res entative shall also be notified 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> in advance of the time articles or materials are ready for inspection or test."
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(t) Procurements Other Than Those Requiring GSI. Pro-curements which do not require Government Source Inspection shall include the following statemen*;:
"The Government has the right to inspect any or all of the work included in this order at the supplier's plant."
(m) Procurement Source Data Package. The total data pack-age requirements of the supplied item, including equip-ment record and historical data requirements, shall be specified. These requirements shall be adequate to satisfy acceptance of the supplied item as wellas satisfy th,e applicable data requirements for the end-item as specified in the applicable IRL/IRD.
(n) Process Specifications of Procurement Sources. A list-ing of critical processes shall be specified as defined in the applicable IRL/IRD.
(o) Pressure Vessel Historical Data Requirements. Histori-cal data maintenance on each presaure vessel shall be in accordance with the IRL/IRD. The data shall be maintained and compiled for inclusion into the accept-ance data package, as applicable.
(p) Cleanliness Control. Detailed cleanliness control shall be specified as applicable.
(q) Ordnance Data Requirements. Data maintenance on each ordnance device shall be in accordance with the ap-plicable IRL/IRD.
The data shall be maintained and compiled for inclusion into the acceptance data package and to support lot flight certification.
- 4. Contractor Quality Assurance Personnel at Source
- a. Planning. The contractor may assign resident or itinerant quality assurance personnel at subcontractor or supplier facil-ities. The contractor quality assurance source inspection staffing policy shall be clearly described in the Quality Plan.
As signed repres entatives will implement control through planned documentation which details specific requirements and facilitates the recording of corrective action, periodic surveys and other information necessary to ensure that the subcon-tractor or supplier complies with applicable requirements.
Assignment of quality personnel shall be based on the use of the equipment, the hardware unit cost, the contractor's ex-perience with the source or when one or more of the following exists:
(1) In-process or end-item controls have such an effect on the a rticles that the quality cannot be determined solely by inspection or tests of the procured articles at the con-tractor's plant, or 5-13
(2) Verification tests are destructive in nature and the quality cannot be verified solely by inspections or tests at the contractor's plant, or (3) The environments or test equipment required cannot be feasibly and economically simulated or made available at the contractor's plant, or (4) Past performance or quality history of the subcontractor or supplier is marginal, or (5) Qualification testing is to be performed by other than the prime contractor or major suppliers, or (6) Articles or materials are designated for direct shipment from source to NASA or the using site.
- b. Task Assignment. The contractor shall provide a list of duties, responsibilities, and authorities of his assigned quality assur-personnel to the designated Government quality repre-ance sentative at contractor's facility. Whenboth Government Source Inspection personnel and contractor personnel are utilized at a supplier facility, the list shall also be provided to the Gov-ernment quality representative at the supplier's facility upon issuance of the procurement document.
c.
Interrelated Source Activities. The contractor should organize its source activities so that the services of the assigned con-tractor quality assurance source representative can be made available to other contractors and subcontractors participating in the Space Shuttle program. Affected contractors shall mutually determine the extent of. esponsibility and authority to be assigned for execution of all interrelated quality assur-ance activities to achieve maximu n proficiency without re-dundant performance.
- 5. Government Source Inspection. Source iaspection performed by and for the convenience of the Government on procured articles or materials shall not, in any way, replace contractor source inspection or relieve the contractor of his responsibilities for ensuring product quality. The contractor shall process procure-ment documents through the designated Government quality rep-resentative for determination of the need for Government Source Inspection.
- 6. Receiving Inspection. The contractor shall maintain a documented receiving inspection system which ensures:
- a. That procured articles and materials indicate evidence of inspections and tests performed by the procurement source in accordance with purchase requirements and are accompanied with required inspection and test data.
- b. That articles and materials or accompanying records exhibit l
evidence of contractor and Government Source Inspection, as requir ed.
t l
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That procurement source inspection and test data are accept-c.
able by conducting inspections and tests of selected charac-teristics. As a minimum, receiving inspection and test shall include verification of characteristics and design criteria which have not been source inspected by the contractor and which can be verified without disassembly of the article.
Particular emphasis shall be placed on those characteristics for which nonconformances may not be detected during sub-sequent inspections and tests,
- d. That periodic disassemb!v is accomplished as appropriate for more detailed verification of the specified requirements.
That identification and data retrieval requirements have been e.
met and are maintained; that all required data and records are complete and correct; and that articles and materials can be directly related to applicable procurement source records, f.
That appropriate inspection and test equipment and technical documents are available at the proper places and at the proper times to perform the test and inspections,
- g. That procurement source records for articles and materials having definite characteristics of quality degradation or drift with age and/or use indicate the date and test time or cycle at which useful life was initiated, the life or cycles used, and the date and test ti m e or cycle at which useful life will be expended. The recorde shall be maintained and updated if life or cycle use occurs during receiving inspection activities.
The receiving inspection system shall also ensure that the articles and materials, when required, exhibit evidence of initiation of useful life, the life or cycles used, and the date and test time or cycle at which useful life will be expended.
- h. When required by specification or drawing, chemical analyses and physical tests are performed on test specimens submitted with purchased articles and materials.
- i. That chemical analyses and physical tests are condu,cted ac-cording to the established inspection and/or sampling plan.
J.
That the inspection status of articles and materials is mam-i tained during receiving inspection and test operations. This shall include physical separation and identification of articles and materials according to the following categories:
(1) Items awaiting inspection or test results.
(2) Conforming items.
(3) Nonconforming items.
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k.
That articles and materials and their records clearly indicate their acceptance or nonconformance status when released from receiving inspection and test.
l.
That articles and materials to be released are adequately con-trolled and protected for subsequent handling, storage, or use.
- 7. Receiving Records. Receiving inspection and test records shall be maintained for articles and materials to indicate, as a minimum, date of receipt, accomplishment ci applicable requirements of paragraphs ID503 6a through I, results of inspections and tests, inspection and test procedures utilized, and disposition of the articles or materials. Records shall include copies of pertinent procurement source dcicuments received or an indication of the type of documents received and their location.
8.
Procurement Source Data. Receiving inspection and test results shall se recorded to reflect on a continuous basis the qualitative and quantitative performance of individual sources and the quality histories of the supplied articles and materials. The contractor shall maintain data to aid in the selection of procurement sources based upon these results.
- 9. Post-Award Survey of Procurement Source Operations
- a. General. The contractor shall schedule and conduct post-award surveys of procurement sources based upon:
(1) Type of items being procured.
(2) Known problems or difficulties.
(3) Procurement source quality history.
(4) Fabrication and testing capability.
(5) Remaining period of procurement source performance.
b.
Planning. A s chedule shall be prepared in matrix form and shall include all planned surveys for at least one year in ad-i vance. The schedule shall be maintained throughout the dura-tion of the contract.
- c. Classification. The following types of surveys shall be sched-uled when applicablo:
(1) Premanufacturing Survey. Assurance shall be obtained that there is a complete understanding among all parties con-cerning all contract requirements and that the procurement source is capable of producing a quality product.
(2) Predelivery Survey. Assurance shall be obtained that the first unit to be delivered is in compliance with all contract requirements and that all the following units will be identi-cal to the first.
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(3) Quality Maintenance Survey Assurance shall be obtained that the procurement source is maintaining an effective quality system. A quality maint enance suryey shall be conducted at least annually on major suppliers. Surveys of all other suppliers will be as required.
- d. Reporting. A summary'of survey results shall be documented, including problem areas discovered, with recommendations for timely correction and prevention of deficiencies; also, recom-mendations for followup action.
e.
Unified Survey Activities. The contractor shall establish a joint survey program with other affected Space Shuttle contrac-tors to minimize the number of post-award sr.tveys performed at sources of common hardware. A joint survey planning com-mittee comprised of representatives fron> each major con-tractor shall define e baseline for survey planning, perform-ance, reporting, and followup. Procedures shall be established and documented for administering this effort.
10 Coordination of Contractor Procurement Source Inspections and Teets. The contractor shall coordinate with selected sources to ensure compatibility of procurement source inspections and tests with contractor inspections and tests of the procured article or material. The contractor shall provide technical assistance and training for procurement sources as necessary.
1D504 FABRICATION CONTROLS
- 1. Fabrication Operations. The contractor quality activity shall support fabrication operations, including assembly, to ensure that cha racteristic and design criteria specified in technical docu-ments are obtained and maintained in all contractor fabricated articles. Detailed fabrication documents shall be generated and utilized by perso.'.nel conducting fabrication operations. Fabrica-tion documents shall include or refer to:
- a. Nomenclature and identification of the article to be fabricated,
- b. Tooling, jigs, fixtures, and other fabrication equipment to be utiliz ed.
- c. Characteristics and tolerances to be obtained.
- d. Detailed procedures for controlling processes and cleaning, preservation, and packaging operations.
- e. Special conditions to be maintained such as environmental cont rols, specific cleanlines s levels, and precautions to be observed.
f.
Workmanship standards.
- g. Inspection and test operations to be performed during fabri-cation.
- h. Special handling equipment and protective devices.
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- 2. Article and Material Controls. Controls shall ensure that only conforming articles and materials are released at.d used and those not required for the operation involved are removed from work operation. Articles having definite characteristic s of quality degradation or drift with age and/or use shall be marked to indi-cate the date, test time or cycle the critical life was initiated and the date, test time or cycle the useful life will be expended, and
(
this same information shall be recorded in log books. Recorded.
l data shall be maintained for such articles in accordance with documented requirements. Articles and materials to be fabricated processed in a temperature controlled environment shall be -
or inspected and tested in a similar environment to the extent nec-essary to prevent quality degradation. Contamination sensitive articles and materials fabricated or processed in contamination controlled environments shall be inspected, tested, repaired, or modified in an environment equal to or cleaner than the required fabrication or process contamination control environment.
- 3. Cleanliness / Contamination Cont rol. Contract end-items and all components, parts, etc., which form a part or are supplied with -
it and which are contaminant sensitive, shall be cleaned in ac-cordance with documented procedures to the levels specified in the applicable documents and shall be maintained (refer to par 1D509-4)to that cleanliness level. In addition, the contractor shall develop a Contamination Control Document which shall consist of an index of the methods and procedures used to implement the contamination control r equir ements. These methods and pro-cedures shall cover contract end-item hardware, equipment, pers onnel, and control of such areas as fabrication, a s s embly, inspection, and test. The cleanliness level of contaminant sensi-tive components and assemblies, beginning with acceptance at the subcontractor level and continuing until final acceptance of the item by NASA, shall be referred to in this document.
- 4. Process Controls. The contractor shall implement ' controls for thos e processes where uniform,.high quality cannot be assured by inspection of articles alone. These processes include, but are not limited to metallurgical and chemical processes, metal join-ing processes, bonding processes, plastics application, plating and coating processes, and surface treating processes, a.
General. The quality activity shall ensure the overall process control and NDE (nondestructive evaluation) effort by assuring the following:
(1) Personnel are adequately trained and certified for critical processes and NDE.
(2) Critical techniques and processes have been certified.
(3) Facilities, equipment, and materials have been installed properly and their use and maintenance are controlled.
l (4) Resulting documentation, feedback, and records are con-
- trolled, l
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v (5) Adequate coordination with the cognizant engineering func-tion to assure proper selection of critical process and NDE methods and adequate identification on drawings.
(6) Training and personnel and process certificationprocedures have been written and are acceptable for use.
- b. Nondestructive Evaluation. Nondestructive evaluation methods, such as radiography, ultrasonic testing, dye penetrant inspec-tion, magnetic particle, and other applicable methods, shall be utilized and controlled to ensure high quality hardware. The contractor shall describe in his quality program plan his inte-grated approach to NDE, including organizational assignments, facilities, standards, and procedures. NDE standards shall ben prepared considering the flight hardware configurations and geometry and shall represent as naturally as possible the po-tential variations resulting from fabrication, assembly, test, and flight operations, c.
Process Control Procedures.
(1) Process procedures shall be prepared to implement appli-cable processing requirements and shall include detailed performance and control provisions. The provisions shall describe.ne preparation of the processing equipment and materials; the preparation of the articles or materials to
.b e processed; detailed processing operations; conditions to be maintained during each phase of the process including environmental controls; the methods of verifying the ade-quacy of processing materials, solutions, equipment, en-vironments, and their associated control parameters; and the required records for documenting the results of process inspection, test, and verification. The procedures shall fulfill the applicable test and inspection planning require-ment' of paragraph 1D505 for both the processing and its inspection.
(2) Precision cleaning, contamination control, and cleanliness test processes requir e the implementation of the above controls. Specific cleanliness levels to be maintained for systems, subsystems, and major components shall be in-dicated or referred to on drawings, specifications, or other documents controlling the manufacture and test of those it em s.
(3) The contractor shall maintain an up-to-date listing of all critical process control procedures and critical process specifications used in the fabrication, control, and inspec-tion of the materials and articles fabricated. Critical proc-ess specifications shall be available for NASA r eview.
The contractor shall also furnish similar information from his subcontractors upon request.
(
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- d. Equipment Certification. The contractor shall provide for the certification of equipment for selected processes. Records certifying that tests have been performed and the results of such tests shall be maintained. Equipment shall be recertified as indicated by the results of quality surveys, inspections or tests, or when changes are made which affect process in-teg rity.
- 5. Workmanship Standards. Where samples or visual aids showing acceptable workmanship are necessary, they shall be selected by the contractor subject to review by NASA or its designated quality representative. Standards shall be reviewed and revised or re-placed, as necessary, to satisfy current requirements. Standards shall contain appropriate product acceptance / rejection criteria.
- 6. control of Temporary Installation. The contractor shall control and monitor articles on the vehicle which are to be installed and removed, including shipping and handling protective materials.
Temporary articles shall carry distinct identification. Temporary.
installations and removals shall be recorded on a single log for each vehicle. This log shall be initiated upon introduction of the first temporary installation. This log will be maintained during subsequent efforts throughout the life of the vehicle.
1D505 TESTING, INSPECTIONS, AND EVALUATIONS 1.
Testing, Inspection, and Evaluation
- a. The contractor shall plan and conduct inspections and tests which demonstrate that contract, drawing, and specification requirements have been met on all articles and materials, procured and produced. These shall provide the assurance and documented objective evidence that the quality inherent in the design is maintained throughout the contract,
- b. The contractor shall document within the Quality Plan the integration of the inspection methods used throughout all phases of the contract. The plan shall denote an inspection flow that is in consonance with the manufacturing and test flow with significant inspection stations being identified. The plan shall demonstrate how the use of sampling plans and the quality assurance designee technique to support manufacturing and test operations is integrated into the inspection flow.
2 Inspection and Test Planning. The contractor shall provide the necessary planning functions for the accomplishment of inspec -
tions and tests and an adequate documentation system which sub-stantiates their accomplishment. This planning function shall provide for:
Orderly and timely inspection and testing throughout a11 phases a.
of contract performance; 5-20 2
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- b. Coordination and sequencing of inspection and testing con-ducted at successive levels of assembly to ensure satisfactory articles and materials and to minimize unnecessary testing;
- c. Economical and effective use of equipment, facilities, and personnel;
- d. Availability of calibrated inspection and test equipment; Coordination of inspections and tests conducted by the desig-e.
nated Government quality representative; and f.
Use of hardware chsracteristics which have been identified based on design andend-use consideration (paragraph 1D501-1).
The contractor shrE, during the earliest practical phase of per-formance, conduct a complete review of the requirements of the contract to identify and make timely provision for the special controls, processes, test equipment, fixtures, and tooling require-ments for assuring or assessing product quality. When production jigs, fixtures, tooling masters, templates, patterns, and such other devices are used for inspection, their accuracy prior to release for use shall be a consideration of the contractor's quality and manufacturing planning functions.
3 Test Specifications. The contractor shall review for concurrence, prior to release, test specifications which have been prepared for each test to be performed. Effective implementation of these documents shall be assured through controls administered by the quality activity.
4 Inspection and Test Procedures.
Procedures shall be readily available to inspection and test personnel and shall be physically located at the applicable location at the time of inspection or test. Each procedure shall include, as applicable:
Nomenclature and identification of the test article or material.
a.
- b. Characteristics and design criteria to be inspected or tested, including values and tolerances for acceptance and rejection.
Identification of characteristics and design criteria established c.
for inspection or test by the designated Government quality repr es entative.
- d. Datslied steps and operations to be taken in sequence, including verifications to be made before proceeding.
- e. Cross-reference of characteristics with measuring and/or NDE equipment to be used, specifying range and type.
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M.
f.
Details or instructions for operation of special data recording equipment, or other automated test equipment.
- g. Layout and interconnection of test equipment and articles, h.
Identification of hazardous situations or operations.
- i. Precautions to comply with established safety requirements, ensure safety of personnel, and to prevent damage or degrada-tion of articles and measuring equipment.
J. Environments and other conditions to be maintained, k.
Workmanship standards.
- l. Constraints on inspection or testing.
Special instructions for nonconformances, anomalous occur-m.
rences or results,
- n. Details of sampling plans to be used.
o.
Details of nondestructive evaluations.
5.
Inspection and Test Performance
- a. Inspections and Tests. Inspections and/or tests shall be estab-lished and performed on articles and materials to verify com-pliance with specifications and procedures. The inspections also will include records review. The contractor shall ensure that each inspection and test operation (and to the extent practicable, each fabrication and assembly operation) is traceable to the individual responsible for its accomplish-ment.
(1) Control of Articles (a) Articles shall be inspected and tested inaccordance with l
l applicable technical documents.
l (b) Articles undergoing test shall not be adjusted, modified, repaired, reworked, or replaced except as specified in established documents, or in accordance with the re-quirements of paragraph 1D506 l
l (2) Control of Inspection and Test Environments and Equipment (a) Environments shall be controlled to prevent compro-l mising the quality of the article.
1 (b) Equipment shall be controlled, maintained, and calibrated as specified in procedures for each equipment.
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9 (3) Criteria for Reinspection and Retest. Rsinspection and re-test may be required at any stage of contractor operations after accomplishment of remedial and preventive action when:
(a) The article or material does not meet the contract or contractor specification requirements; or (b) The inspection or test performed is not in accordance with test specifications or inspection and test proce-dures; or (c) Equipment malfunctions occur; or (d) Modifications, repairs, replacements, or rework of the article or material occur after the start ofinspection or testing; or (e) The article or material is subject to drift or degradation during storage or handling; or
~
(f) Specified by MRB (Material Review Board). Retest shall be limited by consideration of remaining usefullife and operating time for qualification.
- b. Qualification Test Articles. The contractor shall verify that the following records and procedures are available:
(1) Manufacturing and inspection records.
(2) End-item inspection and test specifications and procedures. -
(3) Authorized deviations.
(4) Nonconformances.
(5) Approved waiverr.
(6) Removal and ins:allation records.
(7) Operating time r ds.
(8) Change verification records.
(9) Safety procedures.
(10) Emergency shutdown procedures.
(11) Rework and retest criteria.
(12) Procedures for use of special measuring devices.
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- c. End-Item Inspections and Tests. The contractor shall perform
(
inspections and tests of completed end-items intended for de-livery under the contract. Nonconformances discovered prior to start or during and after testing shall be documented and understood prior to succeeding operations. Nonconformances
(
shall be closed out in accordance with paragraph 1D506 prior to shipping. The inspections and tests shall be performed in accordance with the end-item test specifications and proce-dures. In addition to determining contractual conformance, the contractor shall report immediately to NASAand the desig-nated Government quality representative any unusual phenom-enon, occurrence, difficulty, or questionable condition, whose detection and correction is not specifically contained in the applicable requirements in order that necessary actions canbe initiated. The contractor shall stop testing when safety of per-sonnel is in jeopardy or damage tn the end-item or associated test equipment is possible, d.
End-Item Reinspection and Retest. Adjustments, modifications, r.epairs, replacements, or rework after completion of end-item inspections and tests for the purpose of Government acceptance shall require prior approval of the designated Government quality representative. The contractor shall evaluate the con-i ditions involved and recommend to the representative the ex-tent of reinspection and/or retest necessary. Any additional l
rework, repair, or modification which is to be accomplished after the end-item is initially accepted by the contractor must have appropiate planning prepared to cover the work. The planning developed shall be processed and approved in the same manner as original planning.
- a. Pre-Installation Tests. Functional tests or inspections will be performed on components prior to installation into next higher assembly when any of the following circumstances exist:
(1) No previous acceptance test.
(2) Acceptability cannot be verified by test of next higher as-s embly.
(3) A significant time has elapsed since the last test. Such time period shall be determined from the age / life character-istics of the component.
(4) Where the component, once installed in the next higher as-s embly, is difficult to remove and requires significant schedule' time to replace.
(5) Where prior failure history of the component indicates the '
need for pre-installation testing.
(6) Where the component, once installed in the next higher as-s embly, by its failure could damage the next higher as-sembly during test.
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- 6. Inspection and Test Records and Data a.
The contractor shall generate and maintain records and data of all inspections and tests perfor med. The records and data generated shall be appropriate for the particular type, scope, and importance of the inspection or test operation performed and in sufficient detail and extent to provide for complete veri-fication and evaluation of the operations and objectives. Records shall disclose the status of articles and materials and evidence of inspections and tests performed, including the dates, b.
Eouipment Records. The contractor shallprepare, maintain, and uporce the equipment record for each subsystem as a means of documenting its continuing h story. Each record shall be identifiable to the pertinent equipment and shall be maintained in chronological order to account for all fabrication, assembly, inspection, and test operations, as well as idle periods (stor-age) and movements of equipment. Entries shall be complete, self-explanatory, traceable to the individual and organization making the entry, and should include or refer to details such as the following:
(1) Configuration data: parts list, drawings, specifications, changes, and identification data.
(2) Fabrication and assembly history: buildup and disassembly instructions, repairs, rework, and modifications.
(3) Inspection and test records: specifications, procedures, results, variables data.
(4) Nonconformance summary: initial review and MRB actions, remedial and preventive actions, NASA approvals.
(5) Cumulative operating times or cycles.
(6) Maintenance records.
The contractor shall identify the equipment for which records will be prepared, the level of assembly or operation at which they will be initiated, and requirements for submittal or ship-ment to equipment destination. Subsystem records shall be combined into system records. When a subsystem is operated or handled independently, including removal from its system, its record shall be maintained current. The equipment records for pressure vessels shall be prepared and submitted in ac-cordance with the applicable IRL/IRD.
c.
End-Item Acceptance Data Package. The contractor shall pre-pare an acceptance data package for each end-item required by the contract. The data package shall be submitted as specified in the applicable IRL/IRD.
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7 Contractor Quality Assurance Actions f
l
- a. Prior to testing, the contractor's quality activity shall:
(1) Verify that applicable inspection and test documents are i
available and approved.
(2) Ensure that requirements for selection and control of.
articles have been implemented and that test constraints, including environmental considerations, havebeen resolved.
(3) Verify that all test equipment is within calibration require-ments and that all personnel certifications (where certifica-tions are required) are valid.
(4) Notify the proper Government quality representative, where required.
(5) Verify that test faciiity requirements have been implemented and that the facility ad GSEareinthe correct configuration-and ready for test.
(6) Verify the configuration and that the article is ready for test and concur in start of testing.
- b. During testing, the contractor's quality activity shall:
(1) Ensure that testing is accomplished in accordance with test specifications and procedures.
(2) Ensure complete and accurate recording of data and test re sults.
(3) Document rework, repair, or modification occurring during the test operation.
(4) Document nonconformances and their dispositions.
Subsequent to testing, the contractor's quality activity shall:
c.
(1) Ensure proper disposition of articles, l
i (2) Report any additional nonconformances and their disposi-tions.
(3) Ensure that remedial and preventive action has been ac-complished relative to nonconformances.
(4) Verify that test results and reports are accurate, com-plete, and traceable to the tested articles.
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8.
Walk-Through/ Shakedown Inspection. The contractor quality or-ganization shall prepare for and conduct periodic walk-through/
shakedown inspections on the contract end-item in the fabrica-tion and assembly cycle. At NASA's option these inspections shall be to iupport major move points and/or as determined by hard-ware defect rates, routine inspection results, quality trends, and maturity of the manufacturing process. The contractor's quality organization shall identify the major move points in the fabrication and ass embly cycle at which this walk-through/ shakedown inspec-tion will be performed and the major article (s) to be inspected.
The co stractor's quality organization will develop walk-through/
shakedawn inspection planning documentation for workmanship, appear ance, inspection status, and configuration status to be evalu-ated. The cognizant NASA resident representative will be notified in sufficient time to participate in the inspections. A copy of the accepted document shall be provided to NASA at the completion of the walk-through/ shakedown inspection.
- 9. Quality As suranc e Designees. The contractor may develop a systematic technique to designate certain trained and qualified manufacturing and test personnel to represent the quality assur-ance organization in performance of selected inspection functions to the extent tha t it i.3 economically advantageous. The quality control functions of th e designees shall be performed as part of their regular manufact aring and/or test function. This technique shall be described in the Quality Plan. This technique shall in-clude the identification ( f hardware, fabrication processes, manu-facturing flow, and inspection points. The selected inspection and test 9. tions shall exclude those processes, inspections, and tests which are considered critical or cases where reinspection cannot be readily accomplished due to further assembly or installation of the hardware.
10 Vehicle Access Control. Organizational responsibilities shall be designated for all activities in and around the vehicle at all times during manufacture, assembly, test, and checkout to ensure the preservation of inherent quality and reliability achieved by design and construction. To ensure safety of the vehicle, adequate con-trols shall be established and implemented to limit access and maintain required environments during all operations and during periods after completion of vehicle checkout, such as storage.
11 GSE Access Control. Any space Shuttle GSE which directly monitors and or controls the Shuttle vehicle during checkout and launch and which, due to its design, normally requires opening to perform
- modification, inspection, or repair should be included in an access control system after validation and inspection accept-ance.
- 12. Integrity Control. Controls shall be established documented and maintained by the contractor and applicable suppliers to ensure that the integrity of hardware is not jeopardized through such operations as unpacking, receiving, inspection, storage, testing, installation, integration testing and shipping.
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1D506 NONCONFORMING ARTICLES AND MATERIA'.S 1
Nonconforming Article and Material Control. When an article or material, produced or procured by the contractor or its subcon-tractor prior to the time of Government acceptance, does not conform to applicable drawing specifications or other require-ments, it shall be identified as nonconforming, segregated to the extent practicable and held for review action. Articles and mate-rials which have received Government acceptance (see Glossary for definition of " acceptance") shall be subject to the requirements of Section 1D511, Government Property Control. The contractor shall establish a documented systematic technique for the identifi-cation, documentation, and control of nonconforming hardware.
This technique shall provide that all hardware be identified in a manner such that marking will in no way degrade the article's required performance nor be incompatible with the design en-vironment of the article. If too small to mark, the article shall be tagged. This identification shall be made immediately after the nonconformance is noted and/or the hardware is removed, if r
installed. The contractor shall provide a means for contractor,
quality activity acceptance overstamping the previous noncon-formance marking. This will indicate that the nonconforming hardware has been analyzed, cause dete rmined, remedial and preventive action initiated, ar.d acceptability achieved. Hardware procured by the contractor for direct shipment from the vendor or subcontractor to NASA shall not be shipped, with open non-conformance, without prior NASA approval.
2 Nonconformance Reporting and Correction. The contractor shall:
a.
Establish a centro 11ed, closed loop documentation technique for recording, reporting, analyzing, correcting, verifying, and feed-back data on nonconformances (discrepancies) discovered by the contractor, subcontractor and supplier personnel, and the designated Government facility representative (s).
b.
Maintain records of discrepancies and their dispositions. In addition, all records of MRB (Material Review Board) actions will be maintained and available to NASA for review. The documents prepared and issued for each discrepanc.y will con-tain as a minimum:
(1) A unique and traceable number; (2) The nomenclature and identification of the nonconforming article or material; (3) A description of the required characteristic or design cri-teria and the nonconformance; (4) Cause or reason for the nonconformance; (5) Preventive and/or corrective actions taken or r eco m-mended; (6) Disposition (remedial aion) of the nonconforming article or material; 5-28
(7) Initiator of the document; (8) Signatures of authorized personnel; (9) Date that the nonconformance occurred; (10) Type of activity being conducted; e.g., fabrication, assembly, qualification test, systems test, predelivery or preinstalla-tion acceptance test, etc.; reference must be made to appli-cable procedure numbers; (11) Area function or activity responsible for causing thefailure or discrepancy; (12) Classification of the nonconformances (NASA action required /not required); and (13) Reference to documented repair procedures, as applicable, Accumulate nonconformances in summary and trend reports, c.
d.
Com:nence nonconformances recording upon initiation of manu-facturing for development and flight hardware, launch complex, and related support equipment, and continue through all sub-sequent phases of the contract.
(1) Record each nonconformance observed or encountered dur-ing inspection of flight equipment and pertinent GSE in order to initiate corrective action (via MRB,if appropriate).
These recordings will also allow the establishment of quality trends.
(2) Record each failure encountered in testing, checkout, or operation of flight equipment and GSE including those caused by human error, Conduct appropriate analysis and examinationof nonconforming e.
articles, materials, or conditions to determine the cause or reason for the nonconfo rmanc e.
Nonconforming articles or materials may be forwarded to the NASA as requested by the NASA contracting officer,
- f. As a minimum:
(1) Notify responsible contractor or supplier organizational elements of nonconformances and the need for remedialand preventive action.
(2) Assign responsibility for followup of remedial and preven-tive actions to ensure accomplishment.
(3) Conduct timely and effective remedial action to ensure the correction of the article or material.
(4) Conduct timely and effective preventive action to prevent recurrence of the nonconformance including correction of 5-29 t
technical documents, correction of other identical articles or materials at all locations and the prevention of detri-mental side effects.
(5) Appropriately document analyses and remedial and pre-ventive actions.
(6) Closeout nonconformance documentation after verifying that effective remedial and preventive actions have been taken.
(7) Notify the NASA of nonconformances and their related memedial and preventive actions, as established by con >
tract.
- g. Initially review nonconforming articles and materials to de-termine one of the following listed dispositions. When the dis-position affects contract requirements, the NASA contracting officer approval shall be required. Articles and materials shall be withheld from further processing until appropriate approval is obtained.
(1) Waivers / Deviations. Waivers / deviations may be submitted to the contracting officer for approval prior to or as a re-sult of consideration of other dispositions. Each waiver /
deviation shall be submitted with written recommendations.
and proposed remedial and preventive action.
(2) Return to Supplier. When an article or material is found to be nonconforming on receipt, it should be returned to the supplier. The contractor shall provide the supplier with nonconformance information and assistance, as necessary, to permit remedial and preventive action.
(3) Return for Rework or Completion of Operations. If the non-conformance is in the category of " return for completion of operations" or " return for rework to drawings, specifica-tions or procedures," the arti'cle or material shall be re '
turned for rework or completion using establishedtechnical documents and operations. During such rework, the. articles or material shall be resubmitted to normal inspection and/
or test operations.
(4) Repair per Standard Repair Procedure. If a repair is pos-sible and a standard repair procedure is in existence and has been approved by the MRB for use in the specific ap-plication, the repairs may be accomplished in accordance -
with the approved procedure without MRB action. If the procedure is changed, then it will again require full MRB approval.
(5) Scrap. If the article or material is unfit for use, it shall be dispositioned in accordance with Government approved con-tractor procedures foridentifying, controlling, and disposing of scrap. Considerations should be given to alternate use of 5-30
the scrapped article for contractor or NASA training pro-grams, engineering laboratory work, etc., in order to minimize the financial loss resulting from scrap disposi-tions. The contractor shall assure that scrap is accounted for as to its end use, and that it is not to be used for flight hardware. In addition, the contractor sha11 identify remedial actions taken to reduce costs resulting from scrappage of nonconforming articles and materials.
(6) Submit to Material Review Board. When the dispocitions as described rbove are not appropriate, the article or material shall be submitted to the MRB for final disposi-tion.
- h. Articles and materials disposed of without referral to the MRB s' tall be subject to a review of each case by the designated Government quality representative to verify appropriateness of contractor decisions.
3 Material Review Board
- a. Membership. The MRB shall be comprised of at least one con-tractor representative whose primary responsibility is engi-neering and one contractor repres entative whose primary responsibility is product quality, and a NASA quality repre-sentative; however, the MRB may function without the NASA quality representative upon agreement by NASA when dis-positioning nonconformances on articles or materials whose failure would not affect the safety of the crew or success of the mis sion. Contractor members for the MRB shall be selected by the contractor on the basis of technical competence and shall have sufficient authority to make appropriate dispositions of the articles or materials involved. Copies of the MRB actions will be submitted to the NASA representative.
- b. Responsibility. As nonconformances are presented for MRB review, the contractor's quality representative, in conjunction with the other MRB members, shall:
(1) Evaluate material submitted.
(2) Determine or recommend disposition, such as scrap, re-pair, etc., or exercise the option of recommending disposi-tions to the NASA contracting officer.
(3) Approve the method and procedure for repair, when repair is appropriate.
(4) Provide contractor recommendations to the contracting officer concerning nonconformance dispositions requiring his approval and verify implementation after approval is i
obtained.
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(5) Ensure that effective remedial and preventive actions are documented on the nonconformance document.
(6) Ensure that accurate records of MRB actions are main-tained.
c.
MRB Dispositions. Dispositions, other than scrap, require the unanimous agreement of the applicable board members. In de-termining dispositions, the board shall: consider the effect of the nonconformance upon the intended use; classify noncon-formance for processing on a priority basis; review records of earlier review actions affecting the same or like article or material; and consider the recommendations of personnel acting in an advisory capacity. The board shall specify on the nonconformance document one of the following dispositions.
When the disposition affects contract requirements, the NASA contracting officer approval shall be required. Articles and materials shall be withheld from further processing until appropriate approval is obtained.
(1) Waivers / Deviations. Refer to paragraph ID506-2g(1).
(2) Repair. When, in the opinion of the board, an acceptable i
repair is possible, repair action may be authorized. Pro-l cedures shall be established or approved by the MRB to perform this repair. Procedures shall include appropriate inspections and tests to verify the acceptability of the re-pair. Standard repair procedures, if developed, shall be under the control of the MRB. Standard repair procedures shall be under the control of the MRB. Standard repair pro-cedures shall be approved by the MRB, including the NASA quality representative. The MRB may grant authority to ap-i ply these approved standard repair procedures for similar nonconfo rmanc es.
The standa rd repair procedure shall identify ha rdware applicability, ext ent of characteristic nonconformance, detailed instruction for accomplishing the repair, and inspection / test criteria for the repaired article or material. The existence of standard repair procedures shall not relieve the contractor of the responsibility for initiating preventive action to the fullest extent practicable.
(3) Use-As-Is. Nonconformances which the MRB feels are suit-able for use without repair may be authorized for use-as-is.
l The rationale for making a use-as-is disposition shall be documented on the nonconformance report.
(4) Scrap. Refer to paragraph ID506-2g(5).
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d.
MRB Holding Area. The contractor shall establish holding areas for articles and materials submitted to the MRB. These holding areas shall provide for the following:
l (1) Access limited to MRB members, personnel escorted by an MRB member, and quality personneladministering the area.
The contractor sha11 make provisions to prevent unautho'rized 5-32
entrance when area is not attended and to preclude removal of hardware except in accordance with the approved MRB disposition.
(2) Stcrage facility.
(3) Log book for recording location and status of articles and materials.
(4) Posting of the current list of the names of authorized per-sonnel, including MRB members,
- e. Supplier Material Review Board. The contractor may, upon determining that a supplier possesses the capability to meet MRB requirements to the extent approved by NASA or its designated Government quality representative, delegate MRB responsibility to the supplier. The contractor will limit the authority of the subcontractor's MRB dispositions to noncon-formances not requiring waiver action. Nonconformances re-quiring waiver action shall be proces' ad in accordance with the applicable contract provisions.
f.
Repair Controls. The contractor shall prepare manufacturing documents to accomplish repair operations, including standard repairs. Prior to initiation of work, the contractor shall re-view these documents to assure that theyprovide detailed step-by-step instructions, material requirements, dimensional and process parameters, and any other considerations imposed by the MRB disposition. Appropriate inspection and test accom-plishment shall be verified by the contractor to verify the acceptability of the repair. Repair records and data traceable to the affected article shall be maintained on file by the con-tractor.
- 4. Contracting Officer. Nonconformances and dispositions shall be subj ect to the contracting officer's approval as stated above.
Waivers / deviations may be submitted prior to or as a r-sult of 1
MRB action. Each waiver / deviation shall be submitted with written recommendations and proposed remedial and preventive action.
Articles and materials shall be withheld from further processing until appropriate approval is obtained.
1D507 METROLOGY 1.
Metrology Controls. The contractor shall establish and utilize a documented metrology activity to control measurement processes in order to provide objective evidence of quality conformance.
Measurement processes shall be performed in accordance with established written procedures, 2
Acceptance. Prior to use during articles and materials accept-t l
ance, the contractor shall ensure that all measurement standards l
and equipment are inspected and/or tested to ensure conformance with requirements. Documented results of the inspection and/or tests shall be maintained by the contractor.
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- 3. Evaluation. All special measurement standa rds and equipment (e.g., automatic test and checkout equipment) shall be evaluated under intended operating conditions to verify that:
- a. When used in the intended measurement process, the standards and equipment measure the desired characteristics to the re-quired accuracy and provide the desiredindications or records,
- b. Standards ani. equipment are compatible with the configuration of related hardware and environment conditions.
- c. Operating instructions are correct and complete. Documented results of the evaluations shall be maintained by the contractor.
4 Article or Material Measurement Processes. Random and system-atic errors in any article or material measurement process shall not exceed ten percent of the tolerance of the article or material characteristic being measured. Authorization for ex-ception shall be requested from the procuring NASA installation.,
- 5. Calibration Mea surem ent Processes. Random and systematic errors in any calibration measurement process shall not exceed 25 percent of the tolerance of the parameter being measured.
Authorization for exception shall be requested from the procuring NASA installation.
- 6. Calibration controls a.
Facility. The contractor shall have his own or use the services of an outside facility for the calibration of measurement standards and equipment, b.
Traceability. All measurement standards shall be traceable to standards maintained by the National Bureau of Standards or their value(s) shall be derived from a controlled measurement process utilizing a fundamental constant of nature.
c.
Handling, Storage, and Transportation. All measurement stand-ards and equipment shall be handled, stored, and transported in a manner which shall not adversely affect quality or result in hazardous conditions, d.
Ida ntification and Labeling. All measurement standards and
~
equipment shall be uniquely identified and labeled, tagged, or coded to indicate calibration status and due date of next calibra-tion.
- e. Calibration Intervals. Calibration intervals shall be estab-lished and periodically reviewed to maximize the availability of measurement standards and equipment without adversely affecting quality. Intervals shall depend upon the use, accuracy, type of standard or equipment, required precision, a'nd other conditions adversely affecting the measurement process.
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f.
Recall System. All standards and equipment used in measure-ment processes shall be recalled and recalibrated at established intervals. Standards and equipment not recalibrated before the recall due date shall be removed from service or otherwise re-stricted from use. Authorization for exception shallbe obtained from NASA. Controls shall be established to ensure the im-mediate recalibration or removal from service of those found to exceed the established intervalor which for any reason might have an adverse effect on quality,
- g. Calibration Records. The contractor shall maintain individual records of measurement standards and equipment. These rec-ords shall include, but not be limited to, the following:
(1) Identification of standard or equipment to be calibrated.
(2) Identification of standard, equipment, and calibration pro-cedure utilized in the calibration process.
(3) Calibration intervals.
(4) Dates and results of each calibration.
(5) Due date of next calibration.
(6) Individual (s) performing calibration.
(7) Calibration facility.
(8) Degree of nonconformance of standards or equipment re-ceived for calibration.
7.
Environmental Requirements. Environmental characteristics (e.g.,
temperature, humidity, vibration, cleanliness) shall be compatible with the accuracy requirements of the article and material and calibration measurement processes.
8 Remedial and Preventive Action. Remedial and preventive action shall be taken relative to nonconforming measurement standards or equipment and shall extend to the article or material measured when such equipment has been used in end item final acceptance tests.
1D508 STAMP CONTROLS
- 1. Stamp Control. The contractor shall establishand maintaina docu-ment ed stamp control technique, including written procedures, that provides for the following:
- a. Stamps, decals, seals, torque wax, paints, signatures, etc.,
shall identify that articles and materials have undergone source and receiving inspection, in-process fabrication and inspection, end-item fabrication and inspection, end-item test-ing, storage, and shipment.
- b. Stamps shall be traceable to individuals responsible for their use and records shall be maintained to identifyindividuals with 5-35
specific stamps. Unissued stamps shall be kept secure to pre-vent unauthorized use. Stamps issued to personnel being trans-6, ferred or terminated shall be returned and sha11not be reissued for a period of at least six months. Worn or damaged stamps shall be destroyed at the time replacements are issued. The identification symbol (number, letter, etc.) of lost stamps shall
.be withdrawn from use for a period of one year before reissue.
The use of any stamp by an individual other than the holder of record is specifically prohibited. Periodic stamp audits shall be conducted to verify that stamps are in the possession of the individuals to whom they are issued.
- c. Stamps shall be applied to records to indicate the fabrication or inspection staias of associated articles and materials.
- d. Stamps shall be applied to tags, cards, or labels attached to individual articles and materials or their containers, as ap-propriate.
- e. Stamps indicating that fabrication, inspection, or test operations have been performed may be applied directly to articles and materials except when this is impractical due to physical limi-tations of the article or such applications will compromise their quality,
- f. Stamping methods and marking materials must be compatible with the articles and their use.
- g. The contractor shall maintain an up-to-date description and explanation of the significance of all stamps and shall have; as a minimum, a unique identification or mark for acceptance, for holding a nonconformance pending MRB disposition, rejection, MRB approval, and specialprocess or nondestructive evaluation and/or inspection acceptances.
- 2. Stamp Restriction. The designs of constactors' stamps shall be such that fabrication and inspection stamps are distinctly different and contractor stamps shall not exhibit the designation " NASA" or abbreviations of any NASA installation.
1D509 HANDLING, STORAGE, PRESERVATION, MARKING, LABELING, PACKAGING, PACKING, AND SHIPPING 1
Procedures and Inst ructions Cont rol. The contractor's quality activity shall reveiw for concurrence, prior to release, those procedures and instructions which describe in detail the controls for handling, storage, preservation, marking, labeling, packaging, packing, and shipping operations. Effectiveimplementation of these documents shall be assured through controls administered by the quality activity.
2 Handling. The contractor's quality activity shall verify that manu-facturing planning documents (routing sheets, operations sheets, travellers, etc.) contain handling instructions and the identification 5-36
of any special handling equipment used to prevent handling damage.
Hardware that may be susceptible to damage shall be provided with special covers, containers, boxes, carts. or vehicles to pre-vent damage during fabrication and processing. All installation, test, and operational sites shall be provided copies of handling instructions to enhance preventive handling damage. Evidence of initial and periodic proof-testing of applicabls handling equipment shall be maintained.
3 Storage. The contractor shall control storage areas for stored articles and materials that are not in woric. The controls shall include:
- a. Controlled acceptance into and withdrawal from the storage area.
- b. Positive identification of limited-life material and removal of materials whose shelf life has expired.
Periodic inspection of stored material, housekeeping, and rec-
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c.
ord keeping,
- d. Systematic inspection and/or testing necessary toinsure main-tenance of preservation, including special environments, for articles in long-term storage.
4.
Preservation. The contractor shan ensure that articles and mate-rials subject to deterioration, corrosion, or contamination through exposure to air, moisture, or other environmental elements dur-ing storage and fabrication are cleaned and preserved by methods which ensure maximum protection consistent with life, and usage.
The contractor shall verify that preservation instructions, includ-ing material and process definition, are contained in the contrac-tor's manufacturing documents and are accomplished.
- 5. Packaging. The contractor shall verify that packaging material, procedures, and instructions are utilized and provide for protection of articles and materials while at the contractor's plant, during transportation to destination, and after arrival at destination. The contractor may utilize existing specifications (industrial or Gov-ernment) or develop and document special specifications to ensure maximum protection. Special attention shall be directed toward critical, sensitive, dangerous or high-value articles. The contrac-tor shall ensure that packaging operations are specified in the manufacturing documents, that sufficient detail is included to en-sure the integrity of the packaging and the hardware, that specific internal environments necessary to prevent degradation of the article or material are included in the packaging. The contractor shall verify the accomplishment of packaging operations.
6.
Packing. The contractor shall perform inspection operations, as necessary, to ensure that articles or materials are ready for packing, are not damaged during packing operations, and that 5-37
packing meets the specified requirements. When reusable con-tainers are to be used, they shall be inspected prior to each use to ensure completeness and suitability.
7.
Marking and Labeling. The contractor rLall ensure that appro-priate marking and labeling for packaging, storage, and shipping of articles and materials is performed in accordance with appli-cable specifications. The marking shall include such information as complete article or material identification, cleanliness level, environmental requirements, package orientation arrows, caution and warning notes, life expiration dates, location of data package; and transportation information, as applicable. Special attention shall be given to critical, clean, sensitive, dangerous, ar.d high-value articles. Tamper-proof decals or labels shall be utilized on precision cleaned articles to permit ready detection of loss of packaging integrity.
- 8. Shipping
- a. Control. The contractor shall implement controls for art!cles-and materials to be shipped from his plant and shall verify that:
(1) All fabrication, assembly, inspection, and testing operations authorized and required to be performed at the plant or test site have been satisfactorily completed.
(2) Articles and materials have been prepared and packaged in accordance with applicable procedures and requirements and have been properly identifiedand marked. Inthe absence of special packing and marking requirements in the con-tract, packing and marking shall comply with Interstate Commerce Commission rules and regulations and shall en-sure safe arrival and ready identification at destination.
(3) Accompanying documents have been properly identified as -
to inspection status by appropriate contractor stamps, and that the data package is complete.
(4) Handling devices and transportation equipment are suitable for the articles and materials involved to prevent damage.
(5) The loading and transportation methods conform to appli-cable specifications and requirements.
b.
Unscheduled Removal. The contractor shall notify the NASA or the designated Government quality representative in the event of any unscheduled removal of an article or material from its container. The extent of reinspection and retest shall be as authorized by the NASA or the designated Government quality repr es entative.
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c.
Acceptance Data Package. The contractor shall include a com-plete documentation package with every shipment. The location of the data package shall be indicated on the exterior of the shipping container.
1D510 SAMPLING PLANS, STATISTICAL PLANNING AND ANALYSIS 1
Sampling Plans. Sampling plans may be used when inspection or tests are destructive or data, inherent characteristics, or the noncritical application of an article or material indicates that a reduction in inspection or testing can be achieved without jeopardiz-ing achievement of quality, reliability, or design intent. When sampling techniques are to be employed, existing military sample inspection documents shall be utilized to the degree practicable.
Sampling plans, other than those contained in existing military documents, may be utilized by the contractor after approval of NASA or its designate'd Government quality representative. The plan (s) shall be as specified in applicable IRL/IRD.
2 Statistical Analysis. Statistical analysis techniques may be used where such use will provide effective control over fabrication and inspection operations, especially in those areas where special processes and equipment are difficult to control. Statistica1 charts may be maintained at a location that will provide maximum pre-ventive action utilization.
1D511 GOVERNMENT PROPERTY CONTROL 1
Contractor's Responsibility
- a. The contractor shall be responsible and accountable for all Government property and associated documentation suppliedby the Government. The contractor shall maintain and update all equipment logs supplied with the equipment,
- b. Controls shall be established, documented, and maintained by the contractor and applicable suppliers to ensure that the in-tegrity of Government property is not jeopardized or compro-mised through all ope. rations including unpacking, receiving inspection, storage, testing, installation, integration testing, and shipping, as 'spplicable. The contractor's Quality Plan will, as a minimum, refsr to the procedures for controlling Government property.
- c. Upon receipt, the contractor shall inspect Government prop-erty to the extent practical to detect damage in transit and to verify that the article and its acceptance data package are complete and the article is as specified in the shipping docu-ments. Under no circumstances shall an article be unpacked and subjected to receiving inspection environment until a re-view has been made of the environmental requirements of the particulas' article to ensure that the integrity of previously accomplished inspection and cleaning procedures is maintained.
Articles found to be serviceable, after packaging has been
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opened, shall be represerved and repackagedunless the articles are to be used immediately,
- d. Should there be evidence of damage in transit, the article shall be inspected to determine the extent of damage.
- e. Receipt of Government property and accomplishment of re-ceiving inspection functions, whether successful or not, shall be recorded in the historical record for the article. This shall include identification of property, dates, types and results of contractor inspections, tests, and other significant events,
- f. Receiving inspection and/or testing functions shall be per-formed by or witnessed by contractor quality personnel. NASA or its designated representative may participate in the in-spection of Government property upon receipt at the contrac-tor's or supplier's plant. The contractor shall functionally test Government property upon receipt or prior to installation into the next level of assembly when required by paragraph ID505-5e.
- g. The contractor shall provide an approved storage area for Government property. Control of this area shall provide for:
(1) Limited personnel access.
(2) Controlled receipt and withdrawal of Government property.
(3) Identification of article status as " Acceptable," " Rejected,"
" Awaiting Test," or " Awaiting Test Results."
(4) Inventory list of articles in the area.
(5) Scheduled inspection of the area and periodic audits of the inventory list.
The contractor shall provide for the protection, maintenance, calibration, periodic inspection, segregation, and controls neces- -
sary to ensure that quality is maintained, that storage areas are adequate, and that damage and deterioration do not occur during handling, storage, installation, or shipment.
- h. Written procedures shall describe the contractor's control over the storage and withdrawal of Government property,
- i. Gove rnment property shall not, be diverted or loaned from its assigr:4 purpose without the prior approval of the NASA Con-i;racting Officer or his designated representative.
J. All testing, assembly, installation, modification, and inspec-tion operations shall be controlled in accordance with docu-mented cleanliness requirements for environment, work sur-faces, tools, fixtures, handling, storage and shipping containers
(
and test and inspection equipment to prevent contamination or other degradation of Government property. Tests and inspec-tions shall be performed to verify article cleanliness prior to 5 40 r-
t use and at established intervals during use to ensure continued cleanlines s.
2 Unsuitable Government Property
- a. Government property found to be damaged or otherwise un-suitable for its intended use shall be identified as nonconform.
ing, segregated to the extent practicable and held for reveiw action. Discrepant Government property shall not be disposi-tioned, reworked, repaired, modified, or replaced without the specific written authorization of NASA.
- b. The contractor shall ensure that all nonconformances are documented and analyzed to ascertain the probable cause.
I When the cause is determined to be in the contractor's opera-tions or activities, corrective action shall be instituted to pre-vent recurrence,
- c. Government supplied property found unsuitable for use during and subsequent to receiving inspection will be reported by the contractor to NASA or its designated representatives. The con-tractor will determine and report the probable cause and necessity for withholding such property from use.
- d. Suppliers having control of Government property for which the contractor is responsible shall report unsuitable property to the contractor and to the delegated Government representative.
1D512 FLIGHT TEST / GROUND OPERATIONS 1
Procedures. The contractor shall develop quality procedures to support the flight test development program and associated ground operations.
2 Planning and Procedural Controls. The contractor shall develop quality planning and procedural controls in conjunction with and in support of horizontal and vertical flight tests and associated ground operations. This activity shall assure as a minimum, the following:
- a. Compatibility with planning and procedural controls,
- b. All quality activities relating to flight test / ground operations such as checkout, servicing, maintenance, and refurbishment are adequately defined.
3 Turnaround Inspection and Test Surveillance. The contractor shall support the turnaround maintenance and ground operations activity to assure that design capabilities of the hardware are maintained and that the quality of the hardware is not degraded. These activ-ities shall include:
- a. Development of specific inspection proced 2res andnondestruc-tive evaluation techniques to be used during safing, turnaround, vehicle ferrying, etc.
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b.
Assurance that maintenance procedures are prepared which include a listing of the inspection and test procedures, test specifications, and processes for NDE techniques and that such documentation is available for site operations,
- c. Support of flight test activities,
- d. Definition of special equipment (NDE) required to perform major inspections,
- e. Development of data collection techniques which are compatible with the launch site operations,
- f. Development of nonconformance reporting and corrective action system.
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APPENDlX A: GLOS'SARY OF TERMS ACCMPTANCE - The act of an authorized agent of the procuring organization by wesich the procuring organization assents to ownership of existing and identifisd contveact items, or approves specific services rendered as partial or complete performance of a contract.
ACCEPTANCE TESTING - Tests to determine that a part, component, sub-system, or system is capable of meeting performance requirements pre-scribed in the purchase specification or other documents specifying what constitutes adequate performance capability for the item in question.
ACCIDENT - An unplanned event which results in an unsafe situation or operational mode.
ACCIDENT PREVENTION - Methods and procedures used to eliminate the causes which lead, or could lead, to an accident.
CERTIFICATION TESTING - Certification tests consist of the subsystem qualification tests and the subsystem higher-level-of-assembly tests plus vehicle level tests. Certification testing does not include exploratory, design verification, development, prequalification, piece-part qualification, accept-ance or checkout tests, except where such tests are required for certification.
COMPONENT - A combination of parts, devic es, and structures, usually self-contained, which performs a distinctive function in the operation of the ove rall equipment. A " black box" (e.g.,
transmitter, encoder, cryogenic pump, star tracker.)
CORRECTIVE ACTION - Action taken to preclude occurrence of an id ntified hazard or to prevent recurrence of a problem.
CREDIBLE ACCIDENT - An accident, the scope and magnitude of which have been defined to allow the design to provide for contingency survival and/or continued operation.
CRITICAL PROCESS - A process which could have adverse effect on ha2d-w are performance as determined through a failure mode and effect analysis, oa hardware designated for fracture coatrol, or on ordnance hardware.
CRITICAL INSPECTION AND TEST ME HOD - An inspection or test methcd Weh is used te, verify a critical process.
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I CRITICALITY CATEGORIES CATEGORY DEFINITION 1
Loss of life or vehicle 2
Loss of mission 3
All others Notes:
I Category 1 inclu is loss or injury to the public.
.' launch abort and launch delay sufficient Category 2 includes bG to cause missa scrub.
DEFECT - A condition of any hardware in which one or more characteristics l
do not conform to the specified requirements.
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DESIGN SPECIFICATION - Generic designation for a specification which describes functional and physical requirements for an article, usually at the component level or higher levels of assembly. In its initial form, the design specification is a s tatement of functional requirements with only.
general coverage of physical and test requirements. The design specification evolves through the project life cycle to reflect progressive refinements in performance, design, configuration, and test requirements.
DESIGNEE - Certain trained and qualified manufacturing and test personnel who represent the contractor quality assurance activity in the performance of selected quality assurance functions.
DEVIATION - A deviation is a specific authorization, granted before the fact to depart from a particular requirement of specifications or related,
documents.
ESCAPE - The utilizatL of quipment or subsystems without outside assist-ance to effect egress from the immediate proximity of danger.
FAIL-OPERATIONAL - The ability to sustain a failure and retain full oper-ational capability for safe mission continuation.
l FAIL-SAFE - The ability to sustain a failure and retain the capability to l
succesr, fully terminate the mission.
FAILQRE - The inability of a system, subsystem, component, or part to perform its required function within specified limits, under specified con-dition i for a specified durath n.
H AZARD - The presence of a potential risk situation caused by an unsafe act E* condiiion, a-2
HAZARD ANALYSIS - The determination of potential sources of danger and recommended resolutions in a timely manner for those conditions found in either the hardware / software systems, the man-machine relationship, or both, which could cause loss of personal capability, loss of system, or loss of life or injury to the public, i
HAZARD LEVELS - A hazard whereby environment, personnel error, de-sign characteristics, procedural deficiencies, or subsystem malfunction i
may result in loss of personnel capability or loss of system shall be cate-gorized as follows:
- a. Catastrophic - No time or means are available for corrective action.
- b. Critical - May be counteracted by emergency action performed in a timely manner,
- c. Controlled - Has been counteracted by appropriate design, safety device s, alarm / caution and warning devices, or special automatic / manual procedures.
INTEGRITY CONTROL-A formalized system established to ensure that only authorized changes, modifications and entries are made to hardware, i
LAUNCH ESSENTIAL GSE - Those items of ground support equipment whose functions are necessary to support the countdown phase and those items of ground support equipment used in pre-countdown phases whose problems can create a safety hazard, cause vehicle damage or inability to detect a vehicle problem.
LIMITED LIFE ITEM - Any item designated as having a limited useful life regardless of whether it is a limited operating life, limited shelf life, oper-atmg life sensitive, or combinations of these. This includes, where appro-priate, fluids, elastomers, and polymers.
LIMITED OPERATING LIFE ITEM - Any item which deteriorates with in-creased accumulation of operating time / cycles and thus requires ' periodic replacement or refurbishment to assure that its operating characteristics have not degraded beyond acceptable limits including consideration for total mission time / cycles and safety factor margins.
LIhGTED SHELF LIFE ITEM - Any item which deteriorates with the passage of time and thus requires periodic replacement, refurnishment, retesting, 1
or operation to assure that its operating characteris*ics have not degraded' beyond acceptable limits.This includes installed as wellac stored components.
LOSS OF PERSONNEL CAPABILITY - Loss of personnel function resultmg in inability to perform normal and/or emergency operations. Also includes loss or injury to the public.
LOSS OF SYSTEM - Loss of the capability to provide the level of system performance required for normal and/or emergency operations.
LOT - Articles produced in a given time sequence with no changes in mate-i rials, tooling, processes, personnel, techniques or configuration, l
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NONCONFORMANCE - A condition of any article or material or service in which one or more characteristics do not conform to requirements. Includes failures, discrepancies, defects, and malfunctions.
OFF-THE-SHELF HARDWARE - Production or existing design hardware (black box, component) used in or for NASA, military, and/or commercial programs.
OPERATING CYCLES - The cumulative number of times an item completes a sequence of activation and return to its initial state; e.g., a switched-on/
switched-off sequence, a valve-opened / valve-closed sequence, tank pressur.
ized/depressurized, or dewar cryogenic exposure / drain.
OPER ATING LIFE - The maximum operating time / cycles which an item can accrue before replacement or refurbishment without risk of degradation of performance beyond acceptable limits.
OPERATING PARAMETER SENSITIVE ITEM - Any item which has a limited life due to variances in its operating parameters (i.e., drift rate in gyro mechanisms) which may not be directly related to operating or calendar time.
ORDNANCE DEVICE FLIGHT CERTIFICATION - An as s essment of each device (by lot) which includes satisfactory premanufacture facility reviews, quality data, and destructive and nondestructive test results.
ORDNANCE LOT (ASSEMBLY)
Those assemblies produced in a given time l
sequence from a single hardware lot and a single explosive lot with no changes in materials, tooling, processes, personnel, techniques, or con-figuration.
OVERSTRESS - A value of any stress parameter in excess of the upper limit of the normal working range er in excess of rated value.
PART - One or more pieces joined together which are not normally subject to disassembly without destruction.
1 Deviated Parts - Parts deviating to some degree from their controlling specification (s).
EEE Parts - EEE (electrical, electronic, and electromechanical) parts l
such as transistors, diodes, microcircuits, resistors, capacitors, relays, connectors, switches, transformers, and inductors.
Substitute Parts - Parts differing from those specified in the approved equipment design.
PROBLEM - Any nonconformance which fits or which is suspected of fitting one of the following categories:
- Failure or unsatisfactory condition occurring during or subsequent to production acceptance testing.
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- Failure or unsatisfactory condition which occurs prior to acceptanc, testing that will or has the potential to adversely affect safety, contribute to schedule impact or launch delay, or result in design change.
- Problem Analysis. Documented results of the investigation performed to determine the cause of the problem.
- Cause (Problem Cause). The event or series of events directly respon-sible for the problem.
- Closed Problem. A problem is closed when the hardwa.e supplier is formally notified of NASA concurrence with the problem analysis (including determination of the cause) and has implemented corrective action to preclude recurrence of the problem after acceptance tests. A lack of corrective action may be acceptable to NASA if analytical / test evidence from the hardware supplier show s that the problem is always detectable during the performance of an established test prior to use and that the problem would not occur
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subsequent to this test.
- Explained Problem. A problem is explained when the supplier is for-mally notified of NASA's concurrence with the problem analysis and rationale for not establishing corrective action. The rationale must establish that a planned mission may proceed withnodetrimentaleffects should the problem recur and that a responsible NASA authority has decided that no corrective action need be established as defined for a closed problem.
- Open Problem. A problem for which responsible NASA management personnel have not approved the problem resolution submittedby the supplier.
The problem is deemed to be open until the supplier is formally notified by NASA that resolutions are acceptable for all deliverable end items for which the problem is applicable.
- Resolved Problem. A problem that has been closed or explained.
PROBLEM REPORTING AND CORRECTIVE ACTION - Acontrolled technique for identification, reporting, analysis, remedy, and prevention of recurrener of problems which occur throughout specified portions of the contract effort.
I RELIABILITY NUMERICAL ESTIMATE - A characteristic of a system or any element thereof expressed as a probability that it will perform its re-quired functions under defined conditions at designated times for specified operating periods.
R_EMEDIAL ACTION - Action to correct a nonconforming article or material.
RESCUE - The utilization of outside assistance by means of personnel, equip-ment, or separately based vehicles to effect a return to a. reasonably perma-nent safe haven.
RESIDUAL HAZARD - Hazard for which safety or warning devices and/or special procedures have not been developed or prov.'ded for counteracting the hazard.
RISK - The chance (qualitative) of loss of personne1 capability, loss of system, 1
or damage to or loss of equipment or property.
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SAFETY - Freedom from chance of injury or. loss of personnel, equipment or property.
SFP (SINGLE FAILURE POINT) - A single element of hardware, the failure of which would lead directly to loss of life, vehicle or mission. Where safety considerations dictate that abort be initiated when a redundant element fails, that element is also considered a single faib e point.
SFPS (SINGLE FAILURE POINT
SUMMARY
) - Summary listing of those sin'-
gle failure points identified in the FMEA. The SFPS amplifies the recom-mended corrective action for elimination or minimization of the effect asso, ciated with each failure mode or the justification for retaining the failure m od e.
SURVIVAL - The utilization of equipment to provide a temporary safe haven to which personnel / crew may escape, and from which rescue may be accom-plished.
SYSTEM SAFETY - The optimum degree of risk management within the con-straints of operational effectiveness, time and cost attained through the application of management and engineering principles throughout a11 phases of a program.
UNSATISFACTORY CONDITION - Any defect for which engineering resolution is required and which requires recurrence control beyond the specific article under consideration. Included in this definition are conditions which cannot be corrected to the specified configuration using the standard planned opera-tions or an event which could lead to a failed condition but does not affect the function of the article such as contamination, corrosion, workmanship requiring engineering disposition, etc.
WAIVER - Granted use or acceptance of an article which does not meet specified requirements; a waivt
- is given or authorized after the fact.
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