National Aeronautics and Space Administration

Presented January 27, 2011, byThe NASA Academy of Program/Project and Engineering Leadershipin collaboration with the NASA CentersLessons Learned Steering Committe

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Space Shuttle Lessons Learned Knowledge Sharing Forum

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The NASA Academy of Program/Project and Engineering Leadership’s Knowledge Sharing initiative, in collaboration with the NASA Centers Lessons Learned Steering Committee, presents

January 27, 2011Kennedy Learning Institute | Kennedy Space Center, FL

http://llis.nasa.gov | http://appel.nasa.gov

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Welcome to Space Shuttle Lessons Learned Knowledge Sharing Forum . . . . . . . . . . . . . . . .5

Agenda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Presentations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

• IntroductoryModule:CapturingKnowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

•ModuleI:KennedySpaceCenterSpaceShuttleLessonsLearned . . . . . . . . . . . . . . . . . . . . . . 16

•ModuleII:MarshallSpaceFlightCenterSpaceShuttleLessonsLearned . . . . . . . . . . . . . . . . 20

•ModuleIII:JohnsonSpaceCenterSpaceShuttleLessonsLearned . . . . . . . . . . . . . . . . . . . . . . 24

•KnowledgeCaptureSessionandGroupReports/BriefingsWorksheet . . . . . . . . . . . . . . . . . . 28

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table of Contents

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Welcome to the Space Shuttle Lessons Learned Knowledge Sharing Forum pilot . As NASA

prepares for the retirement of the Space Shuttle and the development of its replacement, it is timely to

reflectuponthemanyimportantlessonslearnedfromkeyareasoftheSpaceShuttleprogram.Today,

our colleagues fromKennedySpaceCenter,Marshall SpaceFlightCenter, and JohnsonSpaceCenterwill share

personalshuttleprogramstories,insights,andlessonslearned.Itrustbytheendoftheday,weallwillhavelearned

newwaystoshareknowledge,whichcanthenbeleveragedtoimproveourcurrentprocessesandprocedures,aswell

asbenefitthedevelopmentofnewsystemsandfuturecapabilities.

ThisForumisacollaborationbetweentheNASAAcademyofProgram/ProjectandEngineeringLeadershipand

theNASACentersLessonsLearnedSteeringCommittee.Attoday’sone-daypilot,youwillbeintroducedtoNASA’s

LessonsLearnedInformationSystemprocess,content,anduses;learnaboutNASA’scasestudyknowledge-capture

process;andreviewinsightfulSpaceShuttlecasestudiesandlessonslearnedfromKennedy,Marshall,andJohnson.

Yourparticipationisanimportantpartofthesuccessoftoday’sevent.Ourvisionistoevolvethispilotintoatwo-day

agencywideversionoftheSpaceShuttleLessonsLearnedKnowledgeSharingForumthatwillincludeadditionalcase

studiesandlessonslearned,withparticipationfromallNASAcentersthatsupportedtheshuttleprogram.Finally,

thelonger-termgoalistodevelopanofficialAcademyengineeringcoursewithshuttlelessonslearnedatitscore,

complementedbyaSpaceShuttlehistoricaloverview,flightstatistics,anddesignconsiderationsandtradesthatwould

benefitNASApersonnelworkingonfuturespacetransportationsystems.

Bycapturingandsharingknowledgeacrosstheagency,weareestablishingacommunityofreflectivepractitioners,

wherebywewill allbebetter equipped to leverageknowledge thatwill enableNASA tocreatebetterprocesses,

systems,andvehiclesinthefuture.Wehopeyoufindtoday’sForumenlighteningasyouhearlessonsfirsthandfrom

shuttleexperts,offerafewstoriesofyourown,andlearnnewwaystoshareouruniqueknowledgeaswetakeonour

next NASA challenges.

Sincerely,

EdwardHoffman,AcademyDirector,

andtheSSLLKnowledgeSharingForumPlanningTeam

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Agenda

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8:00 a .m . AttendeeRegistrationandMeetandGreet

8:30 a .m . Opening• Welcome

– Pat Simpkins, Director, Kennedy Space Center Engineering and Technolog y Directorate

• OpeningRemarks/ForumOverview/Introductions– Ed Hoffman, Academy Director

• ChargetoParticipants– Stephen Angelillo, Kennedy Space Center Managing Director, Academy Training Center, and Forum Facilitator

8:45 a .m .–10:00 a .m .IntroductoryModule:CapturingKnowledge• LLISIntroduction,Overview,andProcess

– Michael Bell, Lessons Learned Program Manager and Steering Committee Chair

• LearningfromCaseStudies

– BarbaraFillip,GoddardSpaceFlightCenterKnowledgeSharingProjectManager,OfficeoftheChiefKnowledgeOfficer

– Matt Kohut, Academy Communications

• ModuleKnowledgeCapture:RoundtableDiscussions,Reflections,andGroupReports(final10minutes)

10:00 a .m .–10:15 a .m . MorningBreak

10:15 a .m .–NoonModuleI:KennedySpaceCenterSpaceShuttleLessonsLearned– Module Lead: Russel Rhodes, Kennedy Space Center– ModuleLead:GeorgeVeaudry,EngineeringIntegrator,KennedySpaceCenterPlanningandDevelopmentOffice

• KennedySpaceCenterSpaceShuttleLessonsLearnedCaseHistories

• Kennedy Space Center ModuleKnowledgeCapture:RoundtableDiscussions,Reflections,andGroupReports(final10minutes)

Noon–1:15 p .m . CateredNetworkingLunchattheKLI

1:15 p .m .–2:45 p .m .ModuleII:MarshallSpaceFlightCenterSpaceShuttleLessonsLearnedModuleLeads:

– ModuleLead:JodySinger,Deputy,ShuttlePropulsionOffice– Module Lead: Carolyn Griner, NASA (retired)

• MarshallSpaceFlightCenterSpaceShuttleLessonsLearnedCaseHistories

• MarshallSpaceFlightCenterModuleKnowledgeCapture:RoundtableDiscussions,Reflections,andGroupReports(final10minutes)

2:45 p .m .–3:00 p .m . AfternoonBreak

3:00 p .m .–4:30 p .m . ModuleIII:JohnsonSpaceCenterSpaceShuttleLessonsLearnedModuleLead:

– Module Lead: Frank Buzzard, NASA (retired)

• JohnsonSpaceCenterSpaceShuttleLessonsLearnedCaseHistories

• JohnsonSpaceCenterModuleKnowledgeCapture:TableDiscussions,Reflections,andGroupReports(final10minutes)

4:30 p .m .–5:15 p .m .KnowledgeCaptureSessionandGroupReports/Briefings– Stephen Angelillo/Participants

5:15 p .m .–5:30 p .m . Conclusion• Summary/Q&A/Wrap-UpComments

– Stephen Angelillo/Participants

• CallstoAction/ConcludeForum– Stephen Angelillo/Ed Hoffman

• CourseEvaluationSurvey– Participants

Agenda Kennedy Learning Institute • January 27, 2011

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About the Forum ModeratorsWelcome—PatSimpkins,Director,KennedySpaceCenterEngineeringandTechnologyDirectorate

PatrickSimpkinsisthedirectorofEngineeringatKennedySpaceCenter.Inthisposition,heleadsagroupofengineersfrommultipledisciplinesinthedesign,development,andoperationsofspaceflighthardwareandgroundsystemsassignedtoKennedy.HebeganhisNASAcareerin1983asashuttleengineerandservedinvariousrolesofincreasingresponsibilityintheSpaceShuttleprogramforfifteenyears.HepursuedaneducationinhumanresourcemanagementandservedasKennedy’sPersonnelOfficer.AftercompletingtheSeniorExecutiveServiceCandidateDevelopmentProgram,heworkedinhumanresourcesatNASAHeadquartersfortwoyears.

Dr.Simpkinshasbeenarecipientofanumberofawardsandleadershipdevelopmentprogramsthroughouthiscareer.HewasselectedfortheSeniorExecutiveServiceCandidateDevelopmentProgramin2001,wherehereceivedexecutive-leveleducationfromtheUniversityofMichiganandasaHarvardseniorexecutivefellow.HisdevelopmentalassignmentsincludedaroleasprojectmanagerintheIntelligentSynthesisEnvironmentprogramatLangleyResearchCenterandasafacilitatoratNASAHeadquartersinthedesignanddevelopmentoftheNASAStrategicHumanCapitalPlanenablingNASAtoachievethefirst“green”ratinginhumancapitalonthepresident’smanagementagenda.AwardshaveincludedtheAstronauts’SilverSnoopyAwardandtheExceptionalAchievementMedal.

Dr.Simpkinsholdsabachelor’sdegreeinenvironmentalengineeringfromtheUniversityofFloridaandamaster’sinhumanresourcemanagementfromtheFloridaInstituteofTechnology.HereceivedadoctorateinbusinessadministrationfromNovaSoutheasternUniversity.

Opening Remarks/Forum Overview/Introductions—EdHoffman,AcademyDirector

EdHoffmanservesasthedirectoroftheNASAAcademyforProgram/ProjectandEngineeringLeadership.Inthisroleheisresponsibleforthedevelopmentofprogram/projectleadersandengineerswithinNASA.Underhisleadership, the Academy provides the agency’s comprehensive career-development curriculum, consulting services fortechnicalandmissionteams,knowledge-sharingactivitiesandpublicationsthatdisseminatelessonslearned,andspecialstudiesonprogram/projectmanagementandengineering.HeworksbothwithinNASAandexternallywithleadersofindustry,academia,andothergovernmentagenciestobuildtheagency’scapabilitiesinprogram/projectmanagement and engineering.

Dr.HoffmanholdsadoctorateaswellasMasterofArtsandMasterofSciencedegreesfromColumbiaUniversityintheareaofsocialandorganizationalpsychology.HereceivedaBachelorofScienceinpsychologyfromBrooklynCollegein1981.HeservesonthefacultyofTheGeorgeWashingtonUniversityProjectManagementProgram.HeisafoundingmemberoftheInternationalProjectManagementCommittee.Dr.HoffmanservedasthechairoftheProjectManagementInstitute’sGlobalCorporateCouncil,andheisfrequentlyakeynotepresenteratconferencesandassociationevents.Hehaspublishednumerousarticlesandtwobooksonprogramandprojectmanagement,ProjectManagementSuccessStories:LessonsofProjectLeaders(Wiley,2000)andSharedVoyage:LearningandUnlearningfromRemarkableProjects(NASAHistoryDivision,2005).

Charge to Participants—StephenAngelillo,KennedySpaceCenterManagingDirector,AcademyTrainingCenter,andForumFacilitator

AsprogrammanagerfortheAcademyofProgram/ProjectandEngineeringLeadershipatKennedySpaceCenterforthepastthreeyears,StephenAngelillohasplayedasignificantroleinincreasingAcademyawarenessatKennedyandNASA-widebyincreasingefficiencies,standardizingtheKennedyAcademynominationprocess,andworkingwithtrainingandsupport personnel to enhance the experiences and understanding of materials and course products by participants. Also during this time, he improved the Kennedy onboarding program and developed several employee-based tools for resource management,whichhavebeenbenchmarkedbyotherfederalandstateagencies.

Lastyear,withsupportandcooperationfromKennedyseniorleadershipandthedirectoranddeputydirectoroftheAcademy,Mr.AngelilloproposedacentralizedtrainingcenterfortheAcademytobelocatedatKennedy.ThiscenterwillactasaspringboardtobroadenandintroduceAcademy-supportedproductstointernationalpartners,aswellastohighlightKennedycapabilitiesandfacilitiesforparticipants.

Mr.AngelillowasamemberoftheKennedyandFloridaInstituteofTechnologyteam,whichsubmittedaproposaltohostthe2012InternationalSpaceUniversitySpaceStudiesProgram.Thatapplicationwasrecentlyreviewedandaccepted,andtheinstitutionswillbeco-hostingthisesteemedprogramin2012.HehasbeenrecognizedforhiscontinuingdistinguishedlevelofcontributionstotheKennedyHRDevelopmentandRecognitionOffice,theNASAProgram/ProjectManagementDevelopmentprogram,andGlennResearchCenter’sLeadershipUniversity,andhisongoingassistancetoenhanceandprovidetoolsforemployeesandorganizationssotheycanfunctioninamoreefficientworkenvironment.Hewasrecognizedforhisparticipationandsupportofthe2008and2009PMChallengeswiththe2009DistinguishedContributionAward.HealsowasrecognizedbyKennedywithaCertificateofAppreciationforhisoutstandingleadershipandinnovation.

Mr.AngelilloattendedtheCollegeofCharleston’sbusinessprogram,holdsagreenbeltinKAIZEN/LeanSixSigma,andisworkingtowardhisprojectmanagementcertification.Hebringstwentyyearsofbusinessdevelopment,sales,training,andmarketingexperiencetotheAcademy.

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Presentations

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Michael Bell, Kennedy Space Center

TheNASALessonsLearnedInformationSystem(LLIS)isthebackboneoftheNASALessonsLearnedProgram.ThisinformationsystemispartoftheNASAEngineeringNetwork,andtheOfficeoftheChiefEngineerservesastheOfficeofPrimaryResponsibilityforoversightoftheNASAlessonslearnedprocess.NPR7120.6(LessonsLearnedProcess)ispartofthefamilyofengineeringtechnicalrequirementsthatgovernNASA’sprogrammanagementfunctions.TheLLIScapturesexperiencefromsuccessfultests or missions, mishaps or failures; all are excellent sources of learning.

Thissystemenablesself-pacedandcollaborativelearningsoresearchers,designers,orprojectmanagerscansearchandsubmitlessons,helpingemployeesacrosstheagencytolearnfromcollectiveexperience.

Thisbriefingwillreviewthefollowing:

• Lessoncomponents

• Submissionform

• Reviewandapprovalprocess

• Searching

• Taxonomyandlessoncategories

• Repositories

• InterfacewithNASAtechnicalstandards

Barbara Fillip, GoddardSpaceFlightCenter

Matthew Kohut, Academyof Program/ProjectandEngineeringLeadership

Thesessionwillincludeanoverviewofthecasestudyapproach,followedbyadiscussionofselectedSpaceShuttlecase studies.

A.CaseStudyApproachOverview

• Benefitsofcasestudiesanddifferencesbetweencasestudiesandlessonslearned

• Methodologyfordevelopingcasesandintegrationofcasesintrainingsessionsandknowledge-sharingworkshops

• ExistingcollectionsofNASAcases

B.SpaceShuttleCaseStudies

• “InPursuitofImagesofColumbia”

• “Space-to-SpaceCommunicationsSystem”

• “TheLastFlightofColumbia”

• “STS-119Flow-ControlValveIssue”Thecaseshavebeenselectedtoillustratespecificpointsabouteach.

January 27, 2011Introductory Module: Capturing Knowledge

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About the Module Leads

MichaelBellistheprogrammanagerfortheagency’slessonslearnedprogramandservesasthecenter data manager for the Kennedy Space Center. In this position he promotes the collection andsharingofknowledgethroughtheLessonsLearnedInformationSystem,whichisatooltoimproveprojectperformanceandpromotetechnicalexcellence.

BarbaraFillipisaknowledgemanagementspecialistintheOfficeoftheChiefKnowledgeOfficeratGoddardSpaceFlightCenter.ShecametoGoddardasacontractorwithLibraryAssociatesCompaniesinMay2008afterspendingmorethantenyearsworkinginthefieldofinternationaldevelopment,occupyingfunctionsencompassingprogramandprojectevaluation,informationandcommunicationtechnologiesforknowledgesharing,aswellascapacitybuildingandtraining.

MatthewKohutleadsthecommunicationsteamfortheNASAAcademyofProgram/ProjectandEngineeringLeadership.HeservesastheeditoroftheASKtheAcademye-newsletterandoverseesthedevelopmentoftheAcademy’scasestudies.Hehastwentyyears’experiencewritingaboutscientific,technical,andquantitativesubjectsforbothgeneralandexpertaudiences,includingengagementswiththeDepartmentofEnergy,theEnvironmentalProtectionAgency,HarvardUniversity,andtheGermanMarshallFundoftheUnitedStates.

WhAt Are the key lessons leArned And insights gAined from this module?

hoW could nAsA APPly these lessons to imProve its current PrActices And/or develoPment of future systems or cAPAbilities?

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Thepurposeofthis“IntroductoryModule:CapturingKnowledge”KnowledgeCaptureSessionisto

• Reflectuponthekeylessonslearnedandinsightsgainedfromthismodule;

• Discussthem,andtheirimplications,withtheparticipantsatyourtable;and,

• Capturehowtheselessonsmightbeusedtoeffectimprovementsincurrentprocessesorproceduresand/orinthedevelopmentofnewsystemsandcapabilitiesforthefuture.

Thesefindingsandrecommendationswillbesummarizedandpresentedbytheelectedtableleadsduringthefinal“report-out”sessionofthisForum.

NO

TES

WhAt stePs might you tAke to incorPorAte these lessons in your Projects, or cAreer?

PleAse cAPture Any AdditionAl thoughts And reflections thAt you Would like to shAre.

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Module Leads

Russel Rhodes, Kennedy Space Center

George Veaudry, Kennedy Space Center

Theknowledgeofgroundprocessingandthepracticesrefinedduringtheshuttleprogramrepresentauniqueexperiencebase.AGround-ProcessingKnowledge-CaptureLessonsLearnedteamrecentlyledanefforttocaptureknowledgeatKennedySpaceCenter.Theteamidentified184potentiallessonslearnedfromtwelveexistinglaunch-site-supportproduct teams for input into the NASA Lessons Learned Information System.

ManyoftheselessonslearnedentriesconcerntheinterfacebetweentheSpaceShuttlesystemandtheground-processinginfrastructurewithrecommendations,designconsiderations,andrequirementsforhuman-ratedlaunchandrecoveryoperations.Thisinformationwillhaveamajorimpactonfutureprogramsacrosstheagency.

Presenters

Albert Curry,Boeing

Shuttle Orbiter Airlock Hatch Failure on STS-80 (Lessons Learned Entry 4417)

Anthony Chambers,Boeing

Thermal Control System Blanket Interference with Bulkhead Vent Ports (Lessons Learned Entry 2716)

Armand Gosselin and Gabor Tanacs,USA

Flame Trench Refractory (Lessons Learned Entry 3236)

Hal Turner, NASA

Selection and Use of Software Metrics for Software Development Projects (Lessons Learned Entry 3556)

Russel Rhodes, NASA

Space Shuttle Propulsion Systems Ground Processing Lessons Learned (Lessons Learned Entry 2977)

Module I: Kennedy Space Center Space Shuttle Lessons Learned

January 27, 2011

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About the Module Leads

RusselE.RhodesisanativeofthestateofIndiana,whereheearnedaBSinaeronauticalengineeringfromIndianaInstituteofTechnologyin1958,andhasbeenaseniormemberoftheAmericanInstituteofAeronauticsandAstronauticsformorethanfifty-fiveyears.HehasbeenemployedatNASAforfiftyyearsatKennedySpaceCenter.Duringthattime,hehasbeenengagedinthedesign,development,testing,andoperationofballisticmissilesandspacetransportationsystems.Hehasspecializedexperienceinspacevehiclepropellantloading,cryogenic,hydraulics,high-pressuregases,and other propulsion systems.

Mr.RhodeshasservedasasystemsengineerandinengineeringmanagementroleswiththePershing,Redstone,Jupiter,SaturnI/IB,SaturnV/Apollo,Skylab,andshuttleprograms,andheispresentlyengagedintheConstellationprogram.Hehasservedonmishapevaluationteamsbothonandoffcenter,andastheKennedyrepresentativetomanyNASA-sponsoredworkinggroupsandadvisorycommittees.Presently,Mr.RhodesisachartermemberoftheSpacePropulsionSynergyTeam,amemberofthesteeringcommittee,focusingonstrategicaspects of future advanced space-transportation-system technology development and providing affordable access to space.HehasledafunctionalrequirementssubteamanddevelopedseveralstudyproductsinsupportofNASAandothers.Hispublicationsincludeseveraltechnicalpapersonadvancedspacepropulsionandspacetransportationsystems,focusedonloweringthecostofspacetransportationsystemsandprovidingaffordableaccesstospace.

GeorgeVeaudryhasspenthisentireprofessionalcareerwithNASA.AfterobtainingaBachelorofScienceinaeronauticalengineeringfromtheUniversityofFlorida,helaunchedhiscareerin1976asanunpaidKennedySpaceCenterinternworkingontheBicentennialCelebration.Impressedwiththequalityofhisperformanceandhisgeneralworkethic,Mr.VeaudrywasofferedapositionintheShuttleEngineeringDirectorate,workingontheauxiliarypowerunits(APU)andhydraulicssystems.HelaterservedastheleadAPU/hydraulicssystemsengineeratDrydenFlightResearchCenterforthefirstexperimentalshuttleEnterpriseOV-101approachlandingtests.

Sincethattime,hehasheldnumeroustechnicalandmanagementpositionswithinNASAacrossmultipledirectorates,includingchiefoftheFluidsandPropulsionDivisioninthenewlyformedKennedyEngineeringDirectorate.HecurrentlyservesasatechnicalassistantfortheOperationalSystemsEngineeringOfficeresponsibleforthedevelopmentofinnovativepartnershipstoutilizeengineeringresourceswithintheEngineeringDirectorate.HeisalsotheSpaceShuttleKnowledge-CaptureLessonsLearnedprojectlead,whereheandhisteamwereresponsibleforcapturingmorethan190shuttlelessonslearnedfortheagency’slessonslearneddatabase.Hehasservedonmultiplesourceboards,includingtheExplorationGroundLaunchServicesSourceEvaluationBoardaspartofthetechnicalteam,theTechnicalCommitteechairontheNASALaunchServicesBoard,andthePayloadGroundOperationscontractRFPasamemberoftheTechnicalCommittee.HewasalsoselectedtoserveontheMagellanMishapInvestigationBoardasamemberoftheprocessingproceduresinvestigationcommittee.

WhAt Are the key lessons leArned And insights gAined from this module?

hoW could nAsA APPly these lessons to imProve its current PrActices And/or develoPment of future systems or cAPAbilities?

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Thepurposeofthis“ModuleI:KennedySpaceCenterSpaceShuttleLessonsLearned”KnowledgeCaptureSessionisto

• Reflectuponthekeylessonslearnedandinsightsgainedfromthismodule;

• Discussthem,andtheirimplications,withtheparticipantsatyourtable;and,

• Capturehowtheselessonsmightbeusedtoeffectimprovementsincurrentprocessesorproceduresand/orinthedevelopmentofnewsystemsandcapabilitiesforthefuture.

Thesefindingsandrecommendationswillbesummarizedandpresentedbytheelectedtableleadsduringthefinal“report-out”sessionofthisForum.

NO

TES

WhAt stePs might you tAke to incorPorAte these lessons in your Projects, or cAreer?

PleAse cAPture Any AdditionAl thoughts And reflections thAt you Would like to shAre.

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Module Leads

Jody Singer, MarshallSpaceFlightCenter

Carolyn Griner, MarshallSpaceFlightCenter

Overthepastthirtyyears,Marshall’sShuttlePropulsionOfficehasplayedakeyroleinthesafeandsuccessfuloperationofthevenerableSpaceShuttle.Thispresentationwillsummarizekeylessonslearnedacrosstheshuttlepropulsionelementsduringthevehicle’s life cycle. Included in this discussion are lessons learned from the reusable solid rocketmotorthatledtotheevolutionofthecurrentmotor,aswellastheimportanceoftestingandpost-flightassessment,adequatelyaddressingminorityopinions,andthedevelopmentofthesevenelementsofgoodflightrationale.ThepresentationwillalsohighlightthehistoryoftheSpaceShuttlemainengine(SSME)alongwithreasons

foritssuccess,includinghowengineeringdisciplinesandpracticeshaveimprovedasissueswiththeSSMEhavebeenresolved.Thereusablesolidrocketboosterchiefengineerwilldiscussalessononunintendedconsequencesexperiencedbytheelement,withbothpositiveandnegativeeffects.Inaddition,thepresentationwilllookatimprovementsmadetothesuperlightweighttankastheresultofmaterialstestingandupgrades.Finally,thesediscussionswillhighlighthowintegratingnewknowledgeintoexistingprocessesledtoimprovementsincost,performance, and safety throughout the Space Shuttle program.

Presenters

Katherine Van Hooser,SpaceShuttleMainEngineChiefEngineer

Space Shuttle Main Engine: Relentless Pursuit of Improvement

Dennis Moore,SpaceShuttleReusableSolidRocketBooster-MotorChiefEngineer

Space Shuttle Propulsion: Reusable Solid Rocket Motor Lessons Learned

David Wood,SpaceShuttleReusableSolidRocketBoosterChiefEngineer

Reusable Solid Rocket Booster Lessons Learned

Parker Counts,Owner,CountsConsultants

Super Lightweight Tank: Development Through Flight

January 27, 2011Module II: Marshall Space Flight Center Space Shuttle Lessons Learned

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About the Module Leads

JodySingercurrentlyservesinadualroleasthedeputyprojectmanagerfortheShuttlePropulsionOffice(SPO)andasthedeputymanagerfortheAresProjectOfficeatMarshallSpaceFlightCenter.AppointeddeputyprojectmanageroftheSPOinOctober2007,shehasservedasthedeputyprojectmanagerfortheAresProjectOfficesinceMarch2010.AsSPOdeputy,sheisresponsibleforthemanufacture,assembly,andflightreadinessoftheprimarySpaceShuttlepropulsionelements:themainengines,externaltank,solidrocketboosters,andmotors.Overhertwenty-five-yearcareerwithNASA,Ms.SingerhasheldnumerousleadershiprolesintheSPO,

includingmanageroftheReusableSolidRocketBoosterProjectOfficeforfiveyearsuntilassuminghercurrentposition.Inthatcapacity,sheoversawtheworkofseveralhundredNASAandcontractorengineersandtechniciansresponsiblefortheflightsafety,performance,andhardwareintegrityoftheshuttle’sreusablesolidrocketmotorandboosterhardware.Shewasalsoresponsibleforensuringthesafetyandviabilityoftheprogramthroughthecriticalground-test program.

Ms.SingerwasappointedtoNASA’sSeniorExecutiveServicein2002andhasreceivednumerousawardsduringherNASAcareer,includingthePresidentialRankAwardforMeritoriousExecutives—thehighesthonorforcareerfederalemployees—inOctober2007.ShealsoreceivedtheSpaceFlightAwarenessLeadershipAwardin2005,theNASAOutstandingLeadershipMedalin2002,andtheExceptionalServiceMedalin1993.ShewasaSpaceFlightAwarenessLaunchHonoreein1991.Ms.SingerreceivedaBSinindustrialengineeringfromtheUniversityofAlabama.

CarolynS.GrinerwasemployedbyNASA,startingasacooperativeeducationengineeringstudentfromFloridaStateUniversityin1964andendingwithherretirementafterthirty-sixyearsinJanuary2001asthedeputycenterdirectorofMarshallSpaceFlightCenter.

Hertechnicalcareerincludedmaterialsandprocessesground-andflight-basedresearch,technicalandprojectmanagement,andleadershipattheexecutivelevelsinNASA.AtNASAHeadquarters,shemanagedtheUtilizationandOperationsDivisionfortheOfficeofSpaceStation.She

returnedtoMarshallasthedirectoroftheMissionOperationsLaboratorytomanagethetechnicaldevelopmentofthePayloadOperationsControlCenterfortheInternationalSpaceStationandtheflightoperationsforseveralSpacelabmissions.Ms.GrinermanagedthePayloadProjectsOfficeforSpacelabandattachedpayloadmissionsontheSpaceShuttle.In1994,shebecamedeputydirectorofMarshall.

Ms.GrinerwasawardedtheDistinguishedServiceMedaltwice;theNASALeadershipMedal;theNASAExceptionalServiceMedal,alsotwice;thePresidentialandRankofDistinguishedExecutiveandthePresidentialRankofMeritoriousExecutive,bothtwice.AsaFellowoftheAmericanAstronauticsandAeronauticsAssociation,shehasservedasatechnicaldirectorandmemberoftheboardofdirectorsandwasapastboardmemberoftheAmerican Astronautics Society.

SheiscurrentlyvicepresidentforNASAprogramsatScienceApplicationsInternationalinHuntsville,Ala.

WhAt Are the key lessons leArned And insights gAined from this module?

hoW could nAsA APPly these lessons to imProve its current PrActices And/or develoPment of future systems or cAPAbilities?

22

Thepurposeofthis“ModuleII:MarshallSpaceFlightCenterSpaceShuttleLessonsLearned”KnowledgeCaptureSessionisto

• Reflectuponthekeylessonslearnedandinsightsgainedfromthismodule;

• Discussthem,andtheirimplications,withtheparticipantsatyourtable;and,

• Capturehowtheselessonsmightbeusedtoeffectimprovementsincurrentprocessesorproceduresand/orinthedevelopmentofnewsystemsandcapabilitiesforthefuture.

Thesefindingsandrecommendationswillbesummarizedandpresentedbytheelectedtableleadsduringthefinal“report-out”sessionofthisForum.

NO

TES

WhAt stePs might you tAke to incorPorAte these lessons in your Projects, or cAreer?

PleAse cAPture Any AdditionAl thoughts And reflections thAt you Would like to shAre.

23

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Module Lead

Frank Buzzard, JohnsonSpaceCenter(retired)

RetiredNASASpaceShuttleChiefEngineerFrankBuzzardwillpresentexamplesofshuttlelessonslearnedintwocategories—betteristheenemyofgoodenoughandflyingwithdesigndeficiencies.Actualflightexperienceexampleswillbeusedtoderivevaluablelessons.Examplesofsuccessfuldesignupgradeswillalsobepresented.

Inaddition,JohnsonSpaceCenterrepresentativeswillsharetheirknowledgeregardingthe ColumbiaaccidentorganizationalcommunicationandhowtheMissionOperations

Directorateincorporateslessonslearned.

Presenters

Frank Buzzard,JohnsonSpaceCenter,SpaceShuttleChiefEngineer(retired)

Space Shuttle Lessons Learned

Rodney Rocha, JohnsonSpaceCenter,AerospaceEngineer,StructuralEngineeringDivision,LoadsandStructuralDynamicsBranch

STS-107 Columbia Accident Case Study: Organizational Silence and Communication Breakdown

Jim Azbell, JohnsonSpaceCenter,DeputyDivisionChief,SpaceTransportationVehicleDivision,MissionOperationsDirectorate

MOD Incorporation of Shuttle Lessons Learned

January 27, 2011Module III: Johnson Space Center Space Shuttle Lessons Learned

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About the Module Lead

FrankBuzzardspentadistinguishedthirty-yearcareerwithNASAattheJohnsonSpaceCenter,retiringin2003afterleadingtheColumbiaInvestigationTaskForce.HethenservedasBarriosTechnologyprogrammanagerfortheInternationalSpaceStation(ISS)missionintegrationcontractuntil2005.DuringhisNASAcareer,Mr.BuzzardservedaschiefengineeroftheSpaceShuttle, chief engineer of the ISS, and ISS program director/senior system integration manager at NASAHeadquarters.HereceivednumerousNASAawards,includingtheDistinguishedServiceandtwoExceptionalServicemedals.

Mr.BuzzardservedasaU.S.Armyhelicopterpilotforfiveyears,followedbyaBSinaerospaceengineeringwithspecialhonorsfromtheUniversityofColoradoin1974asthetopengineeringgraduate.HeservedatGeneralDynamics,SanDiego,asanAtlasCentaurandTitanCentaurtrajectorydesignerbeforecomingtoJohnsonin1976.HereceivedanMSinphysicalsciencefromtheUniversityofHoustonin1981.Mr.BuzzardisretiredandlivesinBryan/CollegeStationandhasanaerospaceconsultingbusiness,SpaceEngineeringConsulting,Inc.

WhAt Are the key lessons leArned And insights gAined from this module?

hoW could nAsA APPly these lessons to imProve its current PrActices And/or develoPment of future systems or cAPAbilities?

26

Thepurposeofthis“ModuleIII:JohnsonSpaceCenterSpaceShuttleLessonsLearned”KnowledgeCaptureSessionisto

• Reflectuponthekeylessonslearnedandinsightsgainedfromthismodule;

• Discussthem,andtheirimplications,withtheparticipantsatyourtable;and,

• Capturehowtheselessonsmightbeusedtoeffectimprovementsincurrentprocessesorproceduresand/orinthedevelopmentofnewsystemsandcapabilitiesforthefuture.

Thesefindingsandrecommendationswillbesummarizedandpresentedbytheelectedtableleadsduringthefinal“report-out”sessionofthisForum.

NO

TES

WhAt stePs might you tAke to incorPorAte these lessons in your Projects, or cAreer?

PleAse cAPture Any AdditionAl thoughts And reflections thAt you Would like to shAre.

27

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Facilitator

Stephen Angelillo, Kennedy Space Center

Roundtablegroupswillspend15minutescompilinganinformativesummaryoftheirgroup’sKnowledgeCaptureSessionnotesfromtoday’sfourModules.Summariesshouldinclude

• Principlelessonslearned;

• Recommendedactionsthatcouldbeundertakentoincorporatethisknowledgein NASA’s current and future activities; and,

• WayswecanusetheseunderstandingstoimproveourcontributionstoNASA’smission.

Groupswillthenchooseateamleadtoreportouttheir3-minutesummarytoallForumattendees.

January 27, 2011Knowledge Capture Session and Group Reports/Briefings Worksheet

29

NO

TES

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31

Additional resources

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Knowledge Sharing Forum Attendees (as of January 21, 2011)

Moses AdokoNASAHeadquartersmoses.adoko-1@nasa.gov

Steve Angelillo Kennedy Space Center stephen.j.angelillo@nasa.gov

Debbie Awtonomow Kennedy Space Center deborah.a.awtonomow@nasa.gov

Jim Azbell JohnsonSpaceCenterjim.a.azbell@nasa.gov

Michael Bell Kennedy Space Center michael.a.bell@nasa.gov

Hal Bell NASAHeadquartersharold.m.bell@nasa.gov

Fred Bickley MarshallSpaceFlightCenterfred.p.bickley@nasa.gov

Frank Buzzard JohnsonSpaceCenter(retired)fbuzzard@verizon.net

Jeff Campbell Kennedy Space Center jeffery.l.campbell@nasa.gov

Steve Cash MarshallSpaceFlightCentersteve.cash@nasa.gov

Anthony Chambers Kennedy Space Center anthony.m.chambers@nasa.gov

Peter Chitko Kennedy Space Center peter.j.chitko@nasa.gov

Parker Counts MarshallSpaceFlightCenterparkercounts@knology.net

Albert Curry Kennedy Space Center albert.k.curry@nasa.gov

Barbara Fillip GoddardSpaceFlightCenterbarbara.fillip-1@nasa.gov

Brent Fontenot JohnsonSpaceCenterbrent.j.fontenot@nasa.gov

Clark Ford Kennedy Space Center clark.d.ford@nasa.gov

Armand Gosselin Kennedy Space Center armand.m.gosselin@nasa.gov

Shawn Greenwell Kennedy Space Center shawn.m.greenwell@nasa.gov

Carolyn Griner MarshallSpaceFlightCenter(retired)carolyn.s.griner@saic.com

Andrew Hocker AmesResearchCenterandrew.j.hocker@nasa.gov

Ed Hoffman NASAHeadquartersehoffman@nasa.gov

Tom Hoffmann Kennedy Space Center thomas.a.hoffmann@nasa.gov

Stefanie Justice MarshallSpaceFlightCenterstefanie.h.justice@nasa.gov

Matt Kohut NASAHeadquartersmattkohut@infactcommunications.com

Steve Lewis Kennedy Space Center steven.m.lewis@nasa.gov

Blaine Lilly OhioStateUniversitylilly.2@osu.edu

Brian Matisak MarshallSpaceFlightCenterbrian.matisak@nasa.gov

Lauren Miller NASAHeadquarterslauren.l.miller@nasa.gov

Dennis Moore MarshallSpaceFlightCenterdennis.r.moore-1@nasa.gov

Brad Neal DrydenFlightResearchCenterbradford.a.aeal@nasa.gov

Janet Parker Kennedy Space Center janet.m.parker@nasa.gov

Stephen Payne Kennedy Space Center stephen.j.payne@nasa.gov

Lewis Peach NASAHeadquarterslpeach43@yahoo.com

Glenn Perez Kennedy Space Center glenn.s.perez@nasa.gov

Heather Rarick NASAHeadquarters/JohnsonSpace Center heather.l.rarick@nasa.gov

Russel Rhodes Kennedy Space Center russel.e.rhodes@nasa.gov

Rodney Rocha JohnsonSpaceCenterrodney.rocha@nasa.gov

Eddie Santiago Kennedy Space Center edgardo.santiago-2@nasa.gov

Pat Simpkins Kennedy Space Center patrick.a.simpkins@nasa.gov

Jody Singer MarshallSpaceFlightCenterjody.singer@nasa.gov

Phil Sumrall MarshallSpaceFlightCenterjohn.p.sumrall@nasa.gov

Gabor Tanacs Kennedy Space Center gabor.f.tanacs@nasa.gov

Hal Turner Kennedy Space Center harold.h.turner@nasa.gov

Katherine Van Hooser MarshallSpaceFlightCenterkatherine.vanhooser@nasa.gov

George Veaudry Kennedy Space Center george.m.veaudry@nasa.gov

Bob Walker Kennedy Space Center robert.h.walker@nasa.gov

Jeff Wheeler Kennedy Space Center jeff.wheeler-1@nasa.gov

Rita Wilcoxon Kennedy Space Center rita.g.willcoxon@nasa.gov

Tami Wilson Kennedy Space Center tami.l.wilson@nasa.gov

David Wood MarshallSpaceFlightCenterthomas.d.wood@nasa.gov

Clayton Yonce Kennedy Space Center clayton.a.yonce@nasa.gov

Ralph Zerick GlennResearchCenterralph.j.zerick@nasa.gov

33

Lessons Learned Steering Committee Members and Contact Information

Andrew Hocker David Oberhettinger Stefanie Justice

AmesResearchCenter JetPropulsionLaboratory MarshallSpaceFlightCenter

andrew.j.hocker@nasa.gov david.j.oberhettinger@nasa.gov stefanie.h.justice@nasa.gov

650-604-4120 818-393-0952 256-544-9527

Brad Neal Brent Fontenot Eric Traill

DrydenFlightResearchCenter JohnsonSpaceCenter Stennis Space Center

bradford.a.neal@nasa.gov brent.j.fontenot@nasa.gov r.e.traill@nasa.gov

661-276-3204 281-483-6456 228-688-1221

Ralph Zerick Michael Bell (Chair)

GlennResearchCenter Kennedy Space Center

ralph.j.zerick@nasa.gov michael.a.bell@nasa.gov

216-433-5906 321-867-3312

Jerome Kosko Sudha Natarajan

GoddardSpaceFlightCenter LangleyResearchCenter

jerome.g.kosko@nasa.gov s.m.natarajan@larc.nasa.gov

301-286-5584 757-864-7319

nAsA lessons learned information systemknowledge isnot foundwithonlyoneperson,oneproject team,oroneorganization.Sometimes,anotherprojectteam,orperson,knowssomethingthatcanhelp your project oryourtask.Howdoyoufind“it”orthepersonwhoknows“it?”Howdoesknowledgegetfromoneplacetoanother?Aface-

to-facemeeting,e-mail,ortelephonearemethodstraditionallyused.ThenAsA lessons learned Program enables employees to share and find knowledge as easily and as broadly as possible.

Thissystemfacilitatesself-pacedandcollaborative learning.KnowledgesharingatNASAiscriticaltoitssuccess.TheNASALessonsLearnedProgramassiststheagency’sprojectteamsinlearningfromone

another’s on-the-job experiencesandrecommendationsformanagingandmitigatingprojectrisk.LessonsareavailablebysearchingtheNASAEngineeringNetwork.http://llis.nasa.gov/

34

Four skill sets essential to mission success in NASA’s project-based environment

Providing leadership training, advice, direction, and support for the development and learning of the NASA program/project and engineering communities

Under theOffice of theChief Engineer, theAcademy of Program/Projectand Engineering Leadership (APPEL) provides leadership, advice, direction,andsupportforthedevelopmentandlearningof theNASAprogram/projectmanagement and engineering community.

The Academy provides an array of courses, taught by leading industry andNASA practitioners and designed especially for NASA civil servants; facilitates cross-discipline and cross-center knowledge sharing, best practices, andlessons learnedthroughforums,conferences,casestudies, theaward-winning ASK Magazine, and the ASK the Academye-newsletter;andoffersteamsupportand individual mentoring by NASA retirees.

Get to know the Academy, an agencywide resource for technical workforce development, by visiting http://appel.nasa.gov

AC

AD

EM

Y O

F P

RO

GRAM

/ PROJECT & ENGINEERIN

G LE

AD

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SH

IP

Leadership Teamwork Knowledge P r o c e s s

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ASK the Academy is an e-newsletter from the Office of the Chief Engineer that provides a means for regular communication withNASA’stechnicalworkforceaboutbestpractices,lessonslearned,andnew developments at theAgency and throughout theworld. SinceNASAisadecentralizedorganizationinwhichexpertswithinvarioustechnicaldisciplineshavefewopportunitiestolearnabouteachother’swork,ASK the Academyservesasawaytobuildconnectionsandshareknowledgeacrosstheagency.

Tobeaddedtothenewsletterdistributionlist,sendane-mailwithyourname,title,ande-mailaddresstomattkohut@infactcommunications.com.

the Academy

magazineNASA’s ASK Magazine gives program and project managers, engineers, and scientists a way to share expertise and lessons learned with fellow practitioners. This is only one way ASK helps share knowledge as part of NASA’s Academy of Program/Project and Engineering Leadership.

Stories recounting the real-life experiences of practitioners communicate important practical wisdom and best practices that readers can apply to their own projects and environments. By telling their stories, managers, scientists, and engineers share valuable experience-based knowledge and foster a community of reflective practitioners. The stories that appear in ASK are written by professionals just like you, primarily from NASA, but also from other government agencies, academia, industry, and international partners.

Your stories and contributions are what make ASK successful, and we invite you to share your ideas for our future issues. Whether it is your own experience or one you heard about, we would love to hear from you. Our editorial staff can help you shape your experience and learning into a compelling story.

Academy Sharing Knowledge

Managing Editor, Don Cohen: doncohen@rcn.com | Editor, Kerry Ellis: kerry.ellis@asrcms.com

National Aeronautics and Space AdministrationJohn F. Kennedy Space Center

Kennedy Space Center, FL 32899

www.nasa.gov

SP-2011-1-011-KSC

http://appel.nasa.gov