CONFIGURATION MANAGEMENT University Nanosat Program 2 December 2005 George Hunyadi University...

CONFIGURATION MANAGEMENT

University Nanosat Program2 December 2005

George HunyadiUniversity Nanosat Program Systems Engineer

Air Force Research Laboratory / Jackson & Tull

[email protected] / 505-853-6322

2Nanosat-4 Configuration Management Telecon2 December 2005

Agenda

• Purpose of Configuration Management (CM)

• UNP Approach to CM

• UNP CM Plan (AFRL Doc# UN4-0002) Key Points

• Examples


Purpose of Configuration Management

• Helps ensure that all UNP and mission requirements are met

– Configuration Management (CM) processes help to maintain the integrity of baselines established throughout the design process (e.g., functional, allocated, and design baselines)

– Provides for adequate technical review so that the intended design meets all functional requirements (i.e., high-quality)

• Example: implications of mass creep

• Ensures that hardware is consistent with accompanying documentation

– Design and Safety reviews are largely fueled by documentation. But documentation is only as good as the real hardware

– 100% correlation between hardware status and documentation lends confidence to the design

• On the other hand, discrepancies between documentation and actual hardware cast doubt on the entire design, assembly, integration and test cycle

– Consistency between documentation and hardware significantly enhances “flyability”


Purpose of Configuration Management

• Just because the paper design is approved ….

– Doesn’t mean the hardware will be built as intended

– Doesn’t mean there won’t be mistakes in constructing the hardware

– Doesn’t mean the hardware won’t be modified down the road

Functional & Safety Requirements

Paper Design doc’n

Build doc’n

Qualification/verification doc’n

Actual Hardware

CM ensures that hardware is consistent

with accompanying documentation

CM ensures that functional & safety requirements are met through adequate technical review and integrity of baselines


• Configuration management requirements can be tailored according to a program’s tolerance for failure

• Current UNP CM requirements reflect this program’s best effort at tailoring CM efforts to balance risk against cost.

CM General Approach

Failure to meet some functional requirements

Inconsequential from a program perspective

Failure to meet safety requirements

Severe, unacceptable consequences

Reduced CM requirements

Increased CM requirements

Tailored CM strikes a balance between cost of implementation and the risk of failure


Configuration Management Plan (UN4-0002)Key Points

1. Documentation Types

2. Document Sign-off (Review) Requirements

3. Change Management

4. Supplier Integrity

5. Configuration Controls


1. Overview of Documentation Types

• Paper Design Documentation– Requirements– Drawings

• Build Documentation– Procedures– Cert logs

• Qualification/Verification Documentation– Procedures– Test/inspection/ analysis

data products– Cert logs– Reports

• Problem/failure reporting & change management– ECR’s– MDN’s– PFR’s– RFD/W’s from UNP req’s

(process not shown, refer to CM Plan)


Documentation Types

Requirements & Engineering Definition


Documentation Types

Requirements

• Requirements Data

– Nanosat-4 User’s Guide (UN4-0001)

– NASA Safety Requirements (e.g., NSTS 1700.7B, NSTS 13830)

– Internal university mission requirements

– Approved Requests for Deviation and Waiver (RFD/W)

• CM for Requirements Data

– Formal review, release, and control of program requirements documents

• Establishes the requirements baseline

• Ensures integrity of requirements

– Prevents “requirements creep”

– Prevents undocumented assumptions from making their way into the design

– Requirements deviations and waivers are handled systematically through the Request for Deviation/Waiver Form (RFD/W)

• Intended primarily for deviations/waivers from UNP requirements, university may choose to implement their own separate RFD/W process—if so, make sure to clearly demarcate the two processes!


Documentation Types Engineering Definition

• Engineering Definition (Paper Design)

– Drawings, parts lists, specifications

– Approved engineering changes

• CM for Engineering Definition Data

– Formal review, release, and control of engineering data

• Ensures adequate technical review of initially released data

• Use Signature Sheets

• Single repository for engineering data

– Formal implementation of engineering changes

• Ensures adequate technical review of changes to data

• Engineering Change Request (ECR)


Documentation Types

As-Built Configuration Data


Documentation Types As-Built Configuration Data

• As-built configuration data

– Assembly, handling, and inspection procedures

– Certification Logs (aka Assembly Logs, Travelers, etc.)

• Certificates of compliance (CofC’s) for all procured/donated items

• Miscellaneous: documentation of anomalies, check-in/check out logs, mix records, engineering change requests

• CM for As-Built Configuration

– All assembly activities are tracked on a Certification Log (a.k.a Traveler, Assembly Log, etc.)

– Some critical assembly activities are completed according to formal procedures: assembly, handling, inspection procedures

– C of C’s are obtained for all purchased parts and are kept on file

– Anomalies that occur during build are documented and resolved systematically


Documentation Types

Qualification Data


Documentation Types Qualification Data

• Qualification data

– Analysis: structural, thermal, electrical

– Test plans / reports

– Manufacturer’s test reports

– Safety data: FSDP, SVP, MSVP, FCP or ELV equivalent (Flight Competition Winner)

• CM for Qualification Data

– Clearly establish requirements for qualification data

• Many requirements are based on NASA-STD-5003, NSTS 13830, etc

• Requirements vary with the design (e.g., different for powdered metallurgy vs. aluminum structure).

• The required content and format of qualification data must be clearly communicated and understood

– Ensure adequate technical review of qualification data through formal review requirements


2. The Sign-off Process—Document Review

• Review requirements for all teams:

– Adequate technical review is achieved through the use of multiple reviewers with specific areas of expertise

– Different signature requirements for different types of data (see slide 16)

– 100% university internal review and document release by Flight Competition

• Additional review requirements for the Flight Competition Winner:

– DoD to provide additional review for the flight competition winner

– Launch vehicle safety review panel provides an audit of the University Nanosat Safety Assessment


Internal University Review Requirements


Internal University Review Requirements

• Your signature means you have thoroughly reviewed and approved the doc

– If your review wasn’t thorough and a mistake is caught after you signed off, every doc with your signature is now suspect and should be reviewed by another set of eyes.

– Signature process intent is to verify that the doc is correct and should be used.

Your integrity is one of your most important assets as an engineer—don’t risk it for the sake of expediency!

If something’s wrong, say so! Don’t give your approval to items which don’t meet requirements.


3. What to do if there’s a problem:

Change Management

• Formal change processes are highly recommended for all university teams

– Formal change processes are applicable once documents have been released.

– Be wary of changes to internal university requirements. Such changes can have downstream effects that are not immediately evident.

• Formal change processes (with AFRL involvement) are required for the Flight Competition Winner

– Documentation forms the basis for selection, so changes must be reviewed/approved by AFRL

– The design baseline is closely monitored at each review

• Methodologies

– Establish a single repository for data, including a database of released documentation (e.g. a spreadsheet or website directory)

– Identify a single point of contact for CM.

– Changes can be made only by way of an ECR or a release of a document revision that reflects the change and is subject to standard review requirements.

– Changes that impact the requirements should be closely reviewed for alternatives. RFD/W’s may be necessary if alternatives cannot be found.


4. Supplier Integrity

• Material Certifications

– When working with raw materials such as plate aluminum, you must obtain certifications that the material is of the desired composition.

• Certificates of Compliance (C of C’s)

– a statement on the part of the manufacturer that a purchased item complies with advertised specifications

• Manufacturer’s Test Reports and other data (e.g., battery cells, fasteners)

• Use of NASA approved suppliers where possible (e.g., fasteners)

– Although JSC fastener requirements are specified, universities can still purchase fasteners from GSFC approved suppliers

• Listed in the back of 541-PG-8072.1.2 (linked in the “Documents” section of the UNP website)


5. Configuration Control

• Storage of hardware, controlled access

– A locked room or cabinet with controlled access (locked door and sign-in/sign-out) is required for all flight hardware at all times

• Protection against contamination and ESD-related damage (ref. Satellite Fabrication Course)

– Most contamination is due to contact with people (body oils, hair, etc). Use protective clothing and latex gloves when handling flight hardware

– Use a clean room with cleanliness levels in line with your hardware requirements (UNP dictates that you use Class 100k)

– Follow grounding procedures to prevent ESD damage. Be sure that you and the satellite are grounded before you touch the satellite.

• Handling procedures

– Protection during transport and shipping

– Protection against environmental damage


Configuration Management Examples

• Drawing Release

• Changes to a Released Drawing

• Purchased Hardware

• Analysis

• Fabrication: General

• Fabrication: Conformal Coating

• Test: General

• Test: Anomalies


Examples Drawing Release

• Scenario: in preparation for CDR, the team wants to release the battery assembly drawing

• Considerations

– The team’s structural and electrical engineers (REA’s) must review, approve, and sign the assembly drawing along with the individual who prepared the drawing

– The team’s systems engineer must review, approve, and sign the assembly drawing.

– The signature page must reflect internal review of all stakeholders

– Once released, documents should be placed under some form of control, i.e., no changes can be made without the approval from the systems engineer.


Examples

Changes to a Released Drawing

• Scenario: A design change is proposed by winning team following the flight competition review

• Considerations

– Complete an Engineering Change Request (ECR), submit to AFRL. The ECR must contain signature approvals from all disciplines on the university team.

– Any implications to requirements must be highlighted by the preparer of the ECR. In some cases, it may be necessary to write an RFD/W

– AFRL will review the ECR and disposition the change. Once an ECR has been approved, then the change is now part of the baseline.

– The team will build flight hardware in accordance with the ECR.

– Post-release changes can occur for a variety of reasons, including manufacturing deviations, problems, or issues with requirements

– Changes made without adequate review and coordination are made “at risk”. Such changes can cause delays and rejection of hardware


Examples

Purchased/Donated Hardware

• Scenario: a team wishes to buy and use a fastener used in critical application

• Considerations

– Use a pre-approved supplier when purchasing and keep on file all purchase paperwork, including the CofC and Manufacturer’s Test Reports

– Verify required testing and qualification data per JSC 23642 JSC Fastener Integrity Testing Program. Requirements vary depending on fastener use, but plan on purchasing 10% more fasteners that you need plus spares

– When the fasteners are received, store them in a locked cabinet where access is limited to identified individuals, and items are “checked-in” and “checked out” via an access log.

– When installing fasteners verify torque and note torque wrench calibration data, check method of secondary retention, log the installation in a certification log. Two individuals required for all assembly activity.


Examples

Analysis

• Scenario: Structural analysis shows the need to increase the part gauge to achieve factor of safety 2.6 against ultimate failure

• Considerations:

– Analyst works directly with the designer to ensure changes are made

– Drawings must be revised as agreed upon by the designer, structural analyst, and systems engineer. If a drawing has not been formally released, then changes can be made immediately to the CAD model.

– If drawings have been released (e.g., after CDR or the flight competition review), then it will be necessary to issue a formal ECR to change the drawing.

– If the part has already been built, then it may be necessary to build a new part (or design a repair).

– The change in the design must be reflected in the final analysis report. A new analysis report should be released that reflects the design change.


Examples

Fabrication: General

• Scenario: General preparation for fabrication and assembly

• Considerations:

– Written Procedures for assembly and test should be used, particularly for process-sensitive or complex assemblies. Most likely an industry standard process is already available; industry standard processes should be used wherever possible.

– Mandatory Inspection Points (MIPS) must be identified in advance. Independent inspections of MIPs should be coordinated with AFRL

– Mix records maintained for multi-part adhesives and coatings

– Any instruments used during assembly must be calibrated (and within their respective expiration window). Examples: torque wrenches, digital multi-meters, etc. Calibration Info must be included on cert logs where these instruments are used.


Examples

Fabrication: Conformal Coating

• Scenario: A two-part compound, such as Uralane, is used to coat a printed circuit board in order to minimize outgassing and prevent short circuits.

• Considerations

– Test and inspect the PCB prior to coating, log results in a cert log. If the PCB is cleaned, then a test and inspection is required post-cleaning.

– If a digital multimeter is used during testing, note the serial number and Calibration Data in the Certification Log.

– Use an Assembly Procedure for mixing and applying the conformal coating, such as Uralane to the PCB. Log all activities in the Certification Log.

– Create and maintain a Mix Record, including date of application, mix components, expiration date, temperature/humidity, and a physical sample of the mixture.


Example

Test: General

• Scenario: A random vibration test is conducted on the primary structure.

• Considerations:

– Use a random vibration Test Procedure that has been approved by each stakeholder (see review requirements).

– On the Certification Log, note that the test was conducted using the above procedure. This cert log form is simply a continuation of previous logs that document all activities conducted on the hardware.

– At least two individuals must be present at all times during testing (required for entries in the certification logs), and to complete the test procedure.

– Test failures / anomalies must be noted on a Problem Failure Report (PFR); the PFR must be resolved through consultation with all relevant team members

– Test results should be checked thoroughly and made available in a Test Report.


Example

Test: Anomalies

• Scenario: During sine sweep tests, first natural frequency of the structure is found to be lower than the 100Hz program requirement.

• Considerations

– Write a Problem Failure Report (PFR) describing the problem and initiating action on the part of the engineering team (structural engineer / systems engineer)

– Review accelerometer data and analytical results to identify sources of flexibility in the structure.

– If a design change is required, conduct analysis illustrating the effectiveness of the design solution (structural reinforcement? reduced mass?, etc). Document all analysis in a Formal Analysis Report.

– Since the design has likely already been released, write an ECR to document the requested design change. The ECR must be reviewed and signed by the structural analyst and systems engineer

– If approved, changes must be incorporated into the structure. Certification Logs must show step-by-step the additional activity required to make the hardware change.

– Close out the PFR


Configuration Management:“The Devil is in the Details”

• Log every significant event that happens to a part (builds, tests, drops, dings, overcurrent events, etc etc) via certification logs, PFR’s, MDN’s, ECR’s all provide a means to document significant events.

• “Buddy system” two sets of initials on every assembly activity, such as the torquing of fasteners

• Hardware are required to be locked up and access controlled. Parts need to be “checked out” and “checked in”

• You can’t just glue something together, you must also provide records of adhesive mixing (parts used, mix records, durometer test results), and retain mix samples for future use (control as flight hardware)

• CofC’s, materials certs, lot test data, etc required for all purchased/donated parts

• Calibration information shall be logged for all instruments, such as torque wrenches, when used.

• Fasteners: have you identified critical fasteners and required testing? Are the test results on file?

• Mandatory Inspection Points?: AFRL needs to witness at least four (4) weeks notice

CONFIGURATION MANAGEMENT University Nanosat Program 2 December 2005 George Hunyadi University...

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