OPTIMIZED COST Performance Design Methodology

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T h i s r e p o r t i s sub mit ted t o NASA, t h e Mis s ion An al ys is D iv is io n of OART,as p a r t o f t h e f i n a l r ep o r t i n g o n C o n t rac t NAS 2-502 2, Op ti m ized C o s t/ Pe r -form an ce Des ig n M et ho do lo gy o f O rb i t a l T ran s p o r t a t i o n Sy s t em s . T h i s t we l v emonth study w a s i n i t i a t e d i n J u l y 1 96 8 and was p e rf or m ed i n two g e n e r a lp h a s e s : a d a t a r ev i e w a nd a n a l y s i s p h a s e and a sy s te m e v a l u a t i o n p h a s e. Ther e p o r t i n g o f t h e s t u dy i s o r g a ni z e d i n t h r e e v olumes b u t i n c l u d e s s e v e r a l b oo ks i nVolumes 2 and 3. Volume 1 i s a s h o r t summary of t h e compl ete s t ud y, Volume 2c o v e r s t h e p h a se 1 d a t a r ev i ew an d an a l y s i s , and Volume 3 c o v e r s t h e p h a se 2system eva lu at io n. The Stu dy Manager was L. M . McKay; t h e major Task Lea der swere P . T. Gen t le , V . E . Henderson, L . E . Smith , and A. D . Tr au tm an . The NASAT ech n i ca l M o n it o r was C . D . H a v i l l .

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ABSTRACT

The br o ad o b j e c t i v e s of t h i s s t u d y w er e t o g a t h e r h i s t o r i c a l c o s t andp er fo rm an ce d a t a , o r g a n i z e and a n a l y z e t h e d a t a s o t h a t c o s t e s t i m a t i n gr e l a t i o n s h i p s c ou ld b e d e ve l op ed , a nd e v a l u a t e s e v e r a l sy st e m c o n c e p ts f o rs pa ce l o g i s t i c s s u p p or t .

The p r im a r y s o u r c e o f h i s t o r i c ~ a l o s t d a t a was t h e G emi ni an d S a t u r nP ro gr am s a nd c o s t e s t i m a t i n g r e l a t i o n s h i p s dr aw e x t e n s i v e l y o n t h i s e x p e r i e n c eA r an g e o f r eu s e co n cep t s we re ev a l u a t ed and optimum ( l e a s t co s t ) co n cep t sd e f i n e d f o r a v a r i e t y of p rogr am o p t i o n s . T he se i n c l u d e v a r i a t i o n s i n s u cht h i n g s a s c re w s i z e , c a rg o c a p a c i t y , pr ogr am re q ui r e me n ts , e t c . f o r e i t h e rb a l l i s t i c o r l i f t i n g body (M2-F2) e n t r y v e h i c l e s .

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LIST OF FIGURES

Study Task FlowGemini Subsys temsGemin i (F ina l )S-IVB DevelopmentOCPDM-Subsystem DevelopmentOCPDM-Development M i l e s t o n e sOCPDM-Flight T e s t Devel opment Sch ed ule( a ) I n d u s t r i a l A re a A c t i v i t i e s , ( b) R ad ar C a l i b r a t i o n a ndPyro Buildup, ( c ) On Pad Assembly A c t i v i t i e s , (d) On PadT e s t i n g A c t i v i t i e sC ountdown an d M i s ce l l an eo u s Ac t i v i t i e sLaunch Veh i c le Launch Op era t ions Cos tsS up po rt A c t i v i t i e sMain tenanceRecovery Cost ComparisonsPrelaunch Flow Time

R E P O R T N O. G 9 7 515 A P R I L 1969

ivIMGDONAIELL D O U G L A S A i S i T ROWA i i S i " G 5 COIMCgkNPIV

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LIST OF TABLESReuse Category SummaryG em in i T e s t A r t i c l e s - B o i l e r p l a t eG em in i T e s t A r t i c l e s - S t a t i c R e e n t ry V e h ic l eG em ini T e s t A r t i c l e s - S t a t i c A d a pt e r V e h i cl e sG em in i T e s t A r t i c l e s - M i s c e l l a n e o u s T e s t V e h i c l e sHardware Requ i rem entsSubsystem Development TimeDevelopment Program TimeAc t u a l Gem in i Op e ra t i o n s an d Su p p o r t C o s t sAdjus ted Gemini Op era t io ns and Suppor t Cos t sR ec ov er y S i t e C o s t sS i t e Cos t BreakdownWater Recovery CostsT y p i c a l R ecov e ry C o s t sRefurbis hment and Unscheduled S par esDirec t Refurb ishment Manhours

REPORT NO. G97515 APRIL 1969

M C D O N N E L L D O U G L A S A S T R ON A U T IC S C O M P A N YE A S T E R N D I V I S I O N


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1. INTRODUCTION - The purpose of t h e Opt imized Cost /Per fo rmance DesignMethodology s t ud y was t o prov ide a method of us ing cos t as a b a s i c d e s i g np a r am e t er i n i d e n t i f y i n g and d e f i n i n g m ore e co no mi ca l s p a c e t r a n s p o r t a t i o ns y s t em s . T h i s s t u d y was p er fo r me d i n s i x t a s k s a s shown i n F i g u r e 1-1. Task 1i n v o lv e d de v e lo p i ng t h e c o s t d a t a , o r g a n i z in g t h e d a t a by c a t e g o r i e s , a n dd ev e lo p in g c o s t e s t i m a ti n g r e l a t i o n s h i p s . Tasks 2 and 3 d e ve l op e d t h e r e q u i r e -m en ts and t h e p h y s i c a l and f u n c t i o n a l c h a r a c t e r i s t i c s of t h e a l t e r n a t e s p a c e c r a f tsubsys te ms a nd ope r a t ion s . An a n a l y t i c a l c os t m odel was f o r m ula te d i n Ta sk 4 .Task 5 d ev e lo p ed t h e l o g i c , d a t a , and meth od s f o r s y s t e m a t i c a l l y v a r y i n g t h ed e s i g n an d o p e r a t i o n a l s p e c i f i c a t i o n s o f e ac h v e h i c l e c o n f i g u r a t i o n . T as k 6t o o k a l l t h e d a t a a nd t o o l s d e ve lo pe d i n t h e o t h e r t a s k s and t h e n d e t e r m i n e dt h e e co n om i ca ll y optimum d e si g n an d o p e r a t i o n a l p h i l o s o p h i e s , s e n s i t i v i t i e st o pro gram s i z e , l a u nc h r a t e , a n d p a y l o a d s i z e - t h e p r ob le m a r e a s - andt e c h n o l o g y l i m i t a t i o n s .

Th i s book r e po r t s on t he work a c com pl ishe d i n Task 3 . The o b j e c t i v e s o ft h i s t a s k were t o :

1. De f ine th e developme nt p l a ns a nd sc he du l e s f o r th e two spa c e -c r a f t t y p e s , by s u b sy s te m a nd v e h i c l e s y s te m a s a f u n c t i o n o ft h e de g r ee of r e u s e a b i l i t y , a nd t h e amount of i n t e g r a l p r o p u l s i o n .

2 . D ef in e t h e o p e r a t i o n a l c o s t s i n m an ho urs , d o l l a r s , o r o t h e rr e s o u r ce s f o r t h e o p e r a t i o n a l a c t i v i t i e s f ro m p re -l au nc ht h ro u gh l au n c h, o n - o r b i t o p e r a t i o n s , d e o r b i t , r e c ov e r y, a ndr e c e r t i f i c a t i o n f o r e a ch of t h e ve h i c l e s.

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2. SUMMARY - T h i s bo ok do cu me nt s t h e e f f o r t s an d r e s u l t s o f T a sk 3 ,Pro gr am D a ta Rev iew A c t i v i t i e s an d A n a ly s i s . The two ma jo r su b t a sk s w er ed ev e lo p men t p l an s an d s ch ed u les ( S e c t i o n 4 ) a nd t h e o p e r a t i o n a l e f f e c t s up onc o s t s ( S e c t i on 5 ) . I n e a c h c a t e go r y , a b a s e l i n e v a l u e was d e t e rm i ne d f o ro n e p a r t i c u l a r c o n f i g u r a t i o n . The c ha ng e s b e c a u se o f r e q u i r e m e n t s o f t h eo t h e r c o n f i g u r a t i o n s w e r e t h e n d oc um en te d as i n c r e m e n t a l i n c r e a s e s o r c h an ge st o t h e b a s e l i n e v a l u es .

The Gemini and Saturn S-IVB programs were used as t h e h i s t o r i c a l b ac kg ro un df ro m w h ich t h e b a se l i n e d ev e lo p men t p l an an d s ch e d u le s w ere d ev e lo p ed . How-e v e r , each of t h es e tw o p r og r ams h ad u n iq u e q u a l i t i e s w hich w ere co n s id e r e d i nd e v e l op i n g t h e b a s e l i n e s . F or ex am pl e, t h e i n i t i a l c o nc e p t of G em ini e n v i s i o n e du s i n g a pa r aw i ng g l i d i n g r e c o v e r y s ys t em f o r l a n d l a n d i n g . The d e s i g n e v o l ve da ro un d t h i s c on c ep t . The s t r u c t u r e was d e s i gn e d f o r l a r g e l a t e r a l p o i n t- l o a dsfrom a l an d in g sk id sy s t em; w a te r r e co v e r y was an ab o r t mode o n ly .

H ow ev er, d ev elo pmen t sn ag s and d e l a y s i n t h e p a raw ing sy s t em f o r ced ar e d e s i g n t o w a t er l a n d i n g wi t h c o n ve n ti o na l r i n g s a i l p a r ac h ut e s f o r t h e t e r m i n a ll a n d i n g s y s t e m .

The r e s u l t i n g c h a n g e s i n t h e s c h e d u l e a nd t h e d e v el op m en t p l a n made t h et i m e and h ar dw ar e q u a n t i t i e s g r e a t e r t h a n w ould h av e be en r e q u i r e d i f t h ef i n a l c o n ce p t h ad b e en t h e o n l y o ne c o n s i d e r e d . S uc h e f f e c t s we r e c o n s i d e r e di n a r r i v i n g a t a b a s e l i n e va lu e o f 35 months f o r subsys tem development and of45 m onths f o r c om p le ti on of a f i v e - f l i g h t t e s t progra m f o r a b a l l i s t i c ,m o d ul a r, a l l - e x p e n d a b l e v e h i c l e ( c o n f i g u r a t i o n I A ) .

A s i m i l a r M2-F2 v e h i c l e wo uld r eq u i r e two mo nths mo re f o r su b sy s temdevelopment . I t would a l s o r e q u i r e from e i g h t t o t e n months l o n g e r f o r f l i g h tt e s t p ro gr am c o m p l e t i o n. Adding i n t e g r a l u p p e r s t a g e p r op u ls i on w i l l i n c r e a s ehardware r equ i rem ents and development t ime. The t ime increment fo r th ei n t e g r a l p r op u ls i on i s n i n e m on th s f o r s u b sy st em d ev el op me nt f o r t h e b a l l i s t i cv e h i c l e a nd t e n m on th s f o r t h e M2-F2 v e h i c l e . Co mple ti o n o f a f i v e - f l i g h tt e s t p ro gra m f o r t h e v e h i c l e s would t a k e 6 4 months or f rom 7 3 t o 75 months ,r e s p e c t i v e l y .

O p e r a t i o n a l a s p e c t s c o n s id e r e d w er e l au n c h o p e r a t i o n s a nd s u p p o r t , m i s s i o no p e r a t i o n s , AGE a nd f a c i l i t i e s m a i nt e na n c e, r e c o ve r y s i t e l o c a t i o n a n d r e c o v e r yc o s t s , and r e c e r t i f i c a t i o n o r r e fu r bi s hm e n t. The l a un c h o p e r a t i o n s , l a u n c h

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s u p p o r t , and mi s s i o n o p e ra t i o n s a c t i v i t e s w e re d e f i n ed by man ho ur s fo r e ach l aun cha s a f u n c t i o n of v e h i c l e c o n f i g u r a t i o n a nd s i z e , o p e r a t i o n s p hi l o so p h y, a n d s i z e o ft h e t o t a l p ro gram (number of l au n ch es o r l e a r n i n g ) . Reco ve ry s i t e a n a l y s i s i n v o l v e dt h e s t a t i s t i c a l p r ob a b i l i ty o f r e t u r n t o s p e c i f i e d l o ca t io n s.

B ec au se r e c e r t i f i c a t i o n i s c o n t r o v e r s i a l w i t h no e x p e r i e nc e t o s e r v e a s a b a s i sfo r e s t i ma t i n g , t h i s an a l y s i s a ss umes a mid dl e-of -t he -road p o s i t i o n ( co mp ared w i t hp r e v i o u s s t u d i e s ) f o r b o t h t h e m an ho ur s, m a t e r i a l c o s t s , a n d f lo w t im e f o r e a c h con-f i g u r a t i o n . The a n a l y s i s c o n si d er e d s i z e , c o n f i g u r a t io n , a nd p h il os o ph y i n d e t e r -m in in g e q u a t i o n s f o r e s t i m a t i n g t h e c o s t o f e ac h c y c l e an d t h e s e l e c t e d l e a r n i n gra t e s . The i n i t i a l b a s el i n e v al u e i s ab o u t fo u r mon th s; t h i s i s r edu ced t o ab o u ttwo months a t t h e f i f t i e t h u n i t th rou gh t h e c y cl e .

I n v e s t i g a t i o n of AGE and f a c i l i t i e s was l i m i t e d by t h e t i m e and manpower avail-a b l e . Maj or e f f o r t was d ev o t ed t o ev a l u a t i n g t h e e f f e c t s o f o n-bo ard ch ecko u t o ne qu ip me nt a nd f a c i l i t i e s a nd upon t e s t i n g t i m e d u ri n g l a u nc h o p e r a t i o n s a ndr e c e r t i f i c a t i o n .

A s p a r t of t h e an a l y s e s o f T as k 6 , a s p e ct r um o f r e u s e a nd i n t e g r a l l a u n c hc o n c ep t s w er e d e f i n e d f o r t o t a l s ys t em e v a l u a t i o n . The p r o g r e s s i o n o f t h e r e u s ec a t e g o r i e s f ro m f u l l y e x p en da bl e t o f u l l y r e u s a b l e , as shown i n Tab le 2-1, app l y t ob o th t h e b a l l i s t i c ( Co nf ig ur at io n I ) a nd t h e l i f t i n g body ( C o n fi g u r at i o n 11) con-f i g u r a t io n s . For t h e b a l l i s t i c v e h ic l e , a 60 d eg. co ne an g l e was u s ed fo r ca t e -g o r i e s A and B , 40 deg c on e a n g l e f o r t h e o t h e r c a t e g o r i e s . F or t h e l i f t i n g bodyc on fi gu r a ti o n, t h e NASA M2-F2 sh ap e was used. T h e b o o s t e r s w e re t r ea t ed p a ra -m e t r i c a l l y . T a b l e 2- 1

Reuse Category Summary

Maneuver Propu l s ion /Cargo Nodule

Upper S ta ge EnginesUpper Stage Tanks

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The f o l l o w i n g s e c t i o n s d i s c u s s g ro un d r u l e s an d a s s u m p ti o n s ( S e c t i o n 3 ) ,d e v el o pm e n t p l a n s a nd s c h e d u l e s ( S e c t i o n 4 ) , o p e r a t i o n s a nd s u p p o r t ( S e c t i o n 5 ) ,an d s u p p o r t eq u ip m ent (S ec t i o n 6 ) . W i t h i n t h e o p e r a t i o n s an d s u p p o r t s e c t i o n i sd i s c u s s e d p r e l a un c h a nd l a u n c h o p e r a t i o n s , o n - o r b i t o p e r a t i o n s , r e c o v e ry s i t es e l e c t i o n , r e c o v e ry f o r c e s a nd c o s t s , r e c e r t i f i c a t i o n , an d t ur n- ar ou nd t im e.

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3 . GROUND RULES AND ASSUMPTIONS - I n e x e cu t i n g t h e a n a l y s e s d i s c u s s e d ,g r ound r u l e s wer e e s t a b l i s he d a nd a s sum pt ions we re made t o bound t h e sc ope o ft h e a n a l y s e s f o r t h e t i m e a nd manpower a v a i l a b l e . The g u i d e l i n e s f o l l o w e d o rg ro un d r u l e s a ss um ed a r e a s f o l l o w s :

1. H i s t o r i c a l G em in i a nd S a t u r n S-IVB d a t a r e p r e s e n t t h e t r e n d st o b e e x pe ct e d i n f u t u r e s p a c e c r a f t p ro gram s.

2 . The a c t u a l Gemini and Sa tu rn S-IVB deve lopment h i s t o r y ca nb e u s e d t o f o r m u l a t e r e a l i s t i c de ve lo pm en t p l a n s f o r new s p ac e -c r a f t s y s te m s.

3 . Where there i s no h i s t o r i c a l d a t a a va i l a b l e , r e ce n t s t u d i e sw i l l s e r v e a s t h e d a t a b a s e .

4 . The Sa tu rn S-IVB development hi s t o r y i s r e p r e s e n t a t i v e of t h ede ve lopm e n t r e qu i r e d f o r a s p a c e c r a f t h av in g i n t e g r a l u p pe rs t a g e p r o pu l s i on .

5 . The nomina l w a i t t im e i n o r b i t p r i o r t o r e t u r n w i l l b e amaximum of 2 4 h o u r s .

6 . The s p a c e c r a f t w i l l b e i n a q u i e s c e n t s t o r a g e mode w h i l edocked t o t h e s p a c e s t a t i o n ; i t w i l l draw a l l of i t s s u p p o r tpower a nd ga se s f rom th e spa c e s t a t i on .

7 . The e x a c t c o mp o si t io n of a ny g i v e n su bs ys te m h a s l i t t l e e f f e c tupon t h e t o t a l de vel op men t t i m e f o r q u a l i f i c a t i o n o f a l lsubsys tems.

8. The h i s t o r i c a l d e ve lo p me nt s c h e d u l e o f t h e 5 -2 e n g i n e i s r e p r e s e n t a -t i v e o f a n i h t e g r a l u pp er s t a g e p r o p u l s i o n sy s te m e n g i ne s c h ed u l e .

9. A l l b a s e l i n e s ub sy st em c o n ce p ts u t i l i z e e x i s t i n g t ec h no l og y .No te ch no lo gy advance ment i s r e q u i r e d .

1 0 . V e r t i c a l o r h o r i z o n t a l l a n d l a n d in g te ch no lo gy i s de ve lope dby o th e r p r e c e e d ing p r ogr am s .

11. The development program i s d ef in ed t o i nc lu de t h e f i r s t f i v ef l i g h t s - unmanned and manned comb ined .

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1 2 . The l a t e r a l r ang e ( o r c r os s -r ang e ) c ap ab i l i t y (-30) of theb a l l i s t i c v eh ic le w i l l be 150 na m i , and of t h e M2-F2, 600 na m i .

13. The stu dy w i l l cons ider only 300 na m i o r b i t s i n cl i ne d a t50 deg, 70 deg, and 90 deg.

14 . Recovery s i t es w i l l be e x i s t i n g s i t e s w i th i n t h e c o n t i n e n t a lU. S. u n l e s s a new, i d e a l l y l o c a t e d s i t e i s s p e c i f i e d .


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4. DEVELOPMENT PLANS AND SCHEDULES - Based upon t h e McDonnell Dougla sexpe r ien ce w i t h t h e Gemini and Sa tur n S-IVB programs, a ba se l ine de ve lopm e n tp l a n and s c h ed u l e was p r e p ar e d . T h i s i n d i c a t e d t h a t a b a l l i s t i c v e h i c l e ,e i t h e r e x pe n da b le o r r e u s a b l e ( C o n f i g u r a t io n s I A, I B , o r I C ) , c o ul d bede ve lope d and f l i g h t q ua l i f i e d i n 45 m on ths fr om go-a hea d th r ough c om ple tiono f t h e f i f t h f l i g h t . The s ub sy st em s c o ul d b e d e ve lo p ed w i t h i n 35 months.The comparabl e M2-F2 v e h i c l e would re qu i re two months lo ng er f o r subsystemd ev el op me nt a nd u p t o e i g h t mo nt hs l o n g e r f o r v e h i c l e d ev el op me nt a nd q u a l i f i -c a t o n .

The i n c l u s i o n o f up p er s t a g e p r o p u l s i o n w i t h i n t h e s p a c e c r a f t s t r e t c h e sth e de velopm e nt p l a n a nd s c h e d u l e by i n c l u d i n g t h e p a r a l l e l de vel op me nt e f f o r to f th e uppe r s t a g e sys t e m s . Thus , t h e ba se l i ne de ve lopm en t t im e i s i n c r e a s e dt o 54 months f o r t h e s ub sy st em s o f t h e b a l l i s t i c v e h i c l e o r t o 57 months fo rt h e M2-F2 v e h i c l e s . T h i s a l s o l e a d s t o a q u a l i f i e d f l i g h t v e h i c l e ( f i v ef l i g h t s ) i n s i x t y - f o u r months ( b a l l i s t i c ) o r up t o s e v e n t y - t h re e months (M2-F2)

M ajor de ve lopm en t ha r dwar e r e qu i r e m e n t s f o r e a c h sc he du le we re de f i ne d .The b a s e l i n e s c h ed u l e f o r c o n f i g u r a t i o n s I A , I B , I IA, and I I B r e q ui r e d f i v eb o i l e r p l a t e v e hi c l es , t h r e e s t a t i c t e s t e n t r y v e h ic l e s , t h r e e t e s t a d a pt e rs ,a t h e r m a l q u a l i f i c a t i o n v e h i c l e , a nd e l e v e n mock-ups o r t e s t a r t i c l e s . Thea d d i t i o n a l h ar dw ar e t o c o m pl et e t h e t e s t and q u a l i f i c a t i o n p ro gram f o r t h eo t h e r c o n f i g u r a t i o n s was t r e a t e d a s a p e r t u r b a t i o n o f t h i s b as e l i n e .

4 . 1 Gemini and S-IVB Subsys tem Development - The Gemini program madee x t e n s i v e u s e o f s u b c o n t r a c t s , b u t had l i t t l e g ov er nm en t f u r n i s h e d e q ui pm en t(GFE). I n c o n t r a s t , t h e bu lk o f t h e S-IVB sys tem was e i t h e r done in - houseor was GFE ( i . e . t h e e ng i ne s a nd va lv e s ) . The a v a i l a b l e S-IVB da ta ha sl i m i t e d a p p l i c a t i o n t o t h i s p a r t i c u l a r a n a l y s i s , and t h e r em ai ni ng d i sc u s si o nw i l l c on c e n t r a t e upon th e h i s t o r y o f th e Gem in i subsys te m de ve lopm en t wh ic hi s shown i n F ig ure 4-1 .

W i th i n f i v e m on th s a f t e r g o- ah ead , a l l s u b c o n t r a c t s f o r m aj ors u bs y st e ms h ad b ee n p l a c e d e x c e p t t h o s e f o r p r o p u l s i v e d e v i c e s . T hi s l a s tsubsys te m was c o n t r a c t e d e ig h t m on ths a f t e r go -a he ad . I n F i g u r e 4-1, t h es t r u c t u r e h a s b ee n i n c l ud e d f o r c o m p l e te n e ss , a lt h o u gh i t was done by McDonnell

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and i t was d i f f i c u l t t o s e p a r a t e s t r u c t u r a l dev elop me nt from t h e i n t e g r a t i o nt a s k . The r e l a t i o n s h i p b et we en de ve lo pm en t and q u a l i f i c a t i o n f o r t h es t r u c t u r a l s u b s y s t e m i s shown mo re c l e a r l y i n s ec t i o n 4 -2.

The c r i t i c a l p a c i ng i t e m s i n t h e G em ini p ro gr am we re p r o p u l s i o n ,r en dezv ou s r a d a r , and t h e l an d i n g s ys t em. Each had unique problems which weremore a r e s u l t o f t h e ad van ced t ech no l o g y i n vo l v ed t h a n i n t h e s u bs y s tem o rs u b c o nt r a c t or d e f i c i e n c i e s . The be s t known problems were i n t h e l a nd l a n d i ngs y s t em w h ich had t o b e co mp l e t e l y r ed es i g n ed f o r w a t e r l an d i n g s when w e i g h ta nd s c h e d u l e s l i p p a g e f o r c e d a r e d i r e c t i o n o f t h e p ro gr am . A s a r e s u l t , t h el a n d i n g s y s t e m r e q u i r e d a l m os t 4 1 m on th s t o r e a c h q u a l i f i c a t i o n . Developmentc o u l d h a ve be e n c o n s i d e r a b l y s h o r t e r i f i t had s t a r t e d w i t h t h e f i n a l d e s i g nco n cep t .

4 .2 Gemini System Development - The Gemini syste m development fol low edt h e p a t t e r n t h a t ev o lv ed d u r i n g t h e Mercu ry p ro gram. Much o f t h e d eve lo p men tand t e s t ph i losophy re su l t ed f rom th e NASA and McDonnel l expe r i e nce s dur ingt h a t program. The f i r s t l i s t i n g of t e s t s and t e s t a r t i c l e s was p u bl i sh e da b o ut s i x weeks a f t e r go- ah ea d. T h i s l i s t was c o n t i n u a l l y u p da t e d a s t h er e q u i r e m e n t s w er e b e t t e r u nd e r s t oo d , A l s o , t h e i mp a ct o f bu d g e t a ry r e s t r i c -t i o n s w a s n o t ed b y t h e ch ang es i n h ard w are r eq u i r em en t s , and by s ch ed u l es l i p p ag es w i t h a s s i g nmen t o f i n -p ro ces s h a rdw are. Fo r t h e p a ra g l i d e r , how-e v e r , t h e s l i p pa g e f o r c ed r e d e s i g n t o u t i l i z e c o n v e nt i on a l p a ra c h ut e s w i tha t t e n d an t ch an g es t o t e s t h a rd ware an d s y st em d ev e lo p men t s ch ed u l e s .

4 . 2 . 1 Background and Hi s to ry - A f t e r a l e t t e r of i n t e n t was r e ce i ve di n mid-December 1 9 6 1, e f f o r t was s t ep p ed up o n d ev e l o p i n g t h e t e s t p l a n andd eve lo p men t s ch ed u l e s . The i n i t i a l d o cumen t,p u bl i sh ed n ea r t h e end o f J an u a ry ,1962 , c a l l e d f o r s i x b o i l e r p l a t e s , s eve n s t a t i c t e s t v e h i c l es , f o ur s t a t i ca d a p t er s , and s i x m ajor t e s t a r t i c l e s .

I n t h e f a l l o f 1962 , NASA budgetar y p rob lems fo r ced economies whichc au se d two of t h e s t a t i c t e s t v e h i c l e s t o b e c a n c e l l e d . A ls o, as t h e p a r a -g l i d e r pr ogr am s l i p p e d f u r t h e r , t h e f l i g h t q u a l i t y a i r f r a m e p ro du ce d t os up p or t t h e q u a l i f i c a t i o n of t h e p a r a g l i d e r was d i v e r t e d t o t h e p r o d u ct i ona i r f r am e l i n e . T hi s s t a t i c t e s t a r t i c l e w a s r ep l aced b y a d e l ay ed p ro d u c t i o n

10MGDOWINELL DOUtiLAS A S T I R O W A U T I C S COIVIPANW

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0F"TIMIZEL) CBST hPERF ORM ANC E R E P O R T NO. ~ 9 7 5DESIGN METHODOLOGY 15 APRIL 1969

a i r f r a m e , and was s u b s e q u e n t ly us e d a s a c r ew a c c e s s a nd r e c ov e r y t e s tv e h i c l e - a t e s t a r t i c l e r a t h e r th an a s t a t i c t e s t v eh i c l e . The p a r a g l i d e rp ro bl em s a l s o r e s u l t e d i n d e l e t i o n of one b o i l e r p l a t e v e h i c l e .

The ba la nc e o f t h e p la nne d t e s t p rogr am wa s ac c ompl i she d g e n e r a l l y aso r i g i n a l l y c o n ce i v ed . Some t e s t s r e qu i re d g r e a t e r e f f o r t t h a n f i r s t e s t im a te d ,a nd o t h e r s w er e co mp le te d i n l e s s t i m e . By c a r e f u l s c h e du le p la nn ing a ndc o n t i n u o u s u p d a t i n g , b y p r i o r i t y a s s ig n m en t , a nd b y c o n t r o l o f l a b o r a t o r ys t a f f i n g l e v e l s , t h e j o b was c om pl eted e s s e n t i a l l y on s ch ed u le i n s p i t e o fd e l a y s an d fu n di n g r e s t r i c t i o n s .

For t h i s o v e r a l l t e s t p l a n and sc he du le , a bou t 850 s e p ar a te t e s tr e q u e s t s w ere w r i t t e n t o d e f i n e s p e c i f i c t e s t s o n t h e m aj or t e s t h ar dw ar e andmany o f th e sm a l l spec im ens o r s a mple s. A l though a l l o f t he se we r e no t e xe c u te d ,a b o u t 750 s e p a r a t e t e s t r e q u e s t s w er e c om pl et ed . The i n i t i a l t e s t s ch e d u l e sw er e g e n e r a l , c o n s i s t i n g o f t wo p a g es . A s t h e t e s t program became b e t t e rd e f i n e d , t h e t e s t s c h e d u l e grew t o a bo u t 1 4 p a ge s w i t h i n c r e a s e d d e t a i l an ds t a t u s i nf o rm a ti o n . S e v e r al o f t h e t e s t a r t i c l e s s er ve d d u a l p u rp o se s , s uc ha s t e s t o f t h e s y st em an d a s a t r a i n i n g a i d f o r t e s t p e rs o nn el i n t h ep r oc e d ur e s f o r p r o d u c t io n (SST) t e s t . T he se w er e a l s o u t i l i z e d t o t r o u b l e -s h o ot p ro bl em s d u r i n g t h e l a t e r p o r t i o n o f t h e f l i g h t p rogram.

4 .2 .2 Major Test Hardware - The m aj or t e s t h a rd wa re ( t h e b o i l e r p l a t e s ,t h e s t a t i c t e s t v e h i c l e s , t h e t e s t a r t i c l e s , an d t h e mock-ups) q u a n t i t i e s o ft h e G emi ni pr og ra m w er e t h e b a s e f o r t h e h a r dw a r e r e q u i r em e n t s u s e d i n t h i ss t u d y . T a b l e s 4-1 through 4-4 l i s t t h e s e pl an ne d Gem in i a r t i c l e s i n d i v i d u a l l yw i t h a b r i e f d e s c r i p t i o n o f e x p e ri e n ce d u s ag e .

The most exp ens ive t e s t i n g of th e Gemini program was th e ThermalQ u a l i f i c a t i o n t e s t i n g p erformed on t h e t e s t a r t i c l e i d e n t i f i e d a s S/C 3 8.T h i s was us ed t o s i m u l a t e m i s s i o n s i n t h e t e s t c ha mb er s. The v e h i c l e ha dt o be f l i g h t q u a l i t y a l th o u gh i t would never b e f lown , and was prob abl ys u b j e c t e d t o more t e s t i n g t h a n an y o t h e r p i e c e o f t e s t h a rd wa re .

The El ec tr o ni c Systems Tes t Unit (ESTU) was l i t t l e more than a mock-ups t r u c t u r a l l y , a l t h ou g h e l e c t r o n i c a l l y i t was a f l i g h t q u a l i t y s ys te m. I t sp u r po s e was t o h e l p i d e n t i f y c omp on en t i n c o m p a t i b i l i t y an d t o h e l p mi n im i zee l e c t r o m o t i v e i n t e r f e r e n c e b et we en t h e many e l e c t r i c a l an d e l e c t r o n i c component-.

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VOLUME 1 OPTIMIZED COSThPEIRFORMANCE R E P O R T N O. G97515 A P R I L 1969OOK 2 DESIGN METHODOLOGY

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OP TllMlf ED COSThPERFORNIANCE REPORT NO. G975DESIGN bWETbrlQBBLBGV 15 APRIL 1969

The C o m p a t i b i l i t y T e s t U n i t (CTU) c o n t in u e d t h e c o m p a t i b i l i t y i n v e s t -i g a t i o n s t o e ncom pass t h e e n t i r e o p e r a t i n g s p ec t ru m and t h e p h y s i c a l l o c a t i o no f a l l c o mp on en ts . I t a l s o s erv ed a s t h e t e s t a r t i c l e t o e n su re t h a t t h e AGEa nd t h e l a u n c h u m b i l i c a l t o we r w er e f u n c t i o n a l l y c o m p a t i b l e , a nd f u r t h e rf u n c t i o n e d a s t h e t r a i n i n g v e h i c l e b o th a t t h e f a c t o r y and a t t h e l au nc h s i t e .

Becau se t h e r e was much co n ce r n ab o u t t h e h a t ch s e a l s , sp ec imen h a t ch\t e s t s w ere co nd uc te d u s i n g t h e s pe ci me n h a t c h t e s t a r t i c l e s . The t e s t r e s u l t s

d i d much t o s a t i s f y t h a t t h e s e a l s w er e ad e qu a te and t h a t t h e l e a ka g er a t e was n o t e x c e s s i v e . I t a l s o s e r ve d a s a t o o l i n d e v e lo p in g ha t c h r i g g i ngp r o ced u r e .

4 . 2 . 3 Pla n s an d Sch ed u les - Due t o t h e bu d ge t ar y r e s t r i c t i o n s a nd t h es c h e du l e s l i p p a g e s , t h e a c t u a l s c h ed u l e s and t h e t e s t h ar dw a re t o s u p p or tthem w ere l e s s t h a n o r i g i n a l l y pl an ne d. The a c t u a l t e s t program u t i l i z e d f i v eb o i l e r p l a t e s (one a d d i t i o n a l was b u i l t b u t n ot u s e d ) , f o u r s t a t i c t e s t v e h i c l e s ,and s i x t e s t a r t i c l e s . The most s i g n i f i c a n t c ha ng e was t h e e l im i n-a t i o n o f t h r e e s t a t i c t e s t v e h i c l e s . Some t e s t s w ere d e l e t e d w i t h t h e s a i l w i n gc a n c e l l a t i o n , - bu t m os t t e s t i n g w as a c co mp li sh ed b y more e x t e n s i v e u t i l i z a t i o no f e ac h s t a t i c v e h i c l e . A ls o, on e of t h e t e s t a r t i c l e s was much t o o e l a b o r a t ef o r t h e u s ag e it r e c e i v e d , a nd was more l i k e a s t a t i c t e s t v e h i c l e t h a na t e s t a r t i c l e .

The f i n a l t e s t s c h e d u l e and d ev e lo pm e nt p l a n f o r t h e G em ini p ro gr am i sshown i n Fig ure 4 - 2 .

4 . 3 Sa tu rn S-IVB St ag e Development - The Sa tu rn S-IVB s t a g e developmentbe ne f i te d f rom th e development exper ienc es o f th e Thor and Sa tur n S-IV programs .T h i s e x p e r i e n c e p r o v id e d t h e management e x p e r i e n c e s o e s s e n t i a l t o t h es u c c e s s f u l c om p le t io n o f a l a u n c h v e h i c l e s t a g e p r o j e c t . The S a t u rn S-IVB i s t h et h i r d s t a g e of t h e S a t u r n V l a u n c h v e h i c l e , a nd h a s a r e s t a r t a b l e 5-2 e n g i n e .The d eve lop ment p l an s an d s ch ed u le s o f t h i s s t ag e mo st c lo se ly r e semble t h ee x p e c t e d d ev el op me nt of t h e i n t e g r a l u p pe r s t a g e p r o p u l s i o n c o n c e p t s of t h i ss t u d y .

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BPllMILED COSThPERFORMANCE REPORT NO.G975DESIGN METHODOLOGY 15 APRIL 1969

4 . 3 . 1 Backg ro un d an d H i s to r y - The h i s t o r y of t h e S-IVB i s c l o s e l yin t e r w o v en w i th t h a t o f t h e S-IV an d much of t h e t e s t i n g pe r fo r med f o r t h eS-IV w as d i r e c t l y ap p l i c ab l e t o t h e S-IVB. Fo r ex ample , t h e d a t a f ro m S-IVh yd ro ge n t a n k s l o s h t e s t s c a n b e a p p l i e d t o t h e S-IVB, e l i m i n a t i n g t h e n ee df o r m ore l i q u i d hy dr og en t a n k t e s t s . M ajo r t e s t s w er e:

a . S t r u c tu r a l s t a t i c t e s t sb . S t r u c t u r a l dyna mic t e s t sc . F eed s y st e m s t e s t sd . P r o p e l l a n t u t i l i z a t i o n s ys te m t e s t se . F l i g h t c o n tr o l s ys te m t e s t sf . A u x i l i a r y p r o p u l s i o n o r RCS t e s t sg . E l e c t r i c a l t e s t sh . D at a a c q u i s i t i o n s ys te m t e s t si. ECS t e s t s

S in ce t h e S -IVB d ev elo pmen t pr og ram was e s s e n t i a l l y co nd u c t ed co mp le t e lyw i t h i n t h e p ri m e c o n t r a c t o r s o r g a n i z a t i o n , many o f t h e s e t e s t s wh ic h wouldu s u a l l y b e co n d u c ted by a ma jo r su b co n t r ac to r w er e con d u c ted b y D o u g las . T heo n ly su b sy s t em w hich co u ld b e co n s id e r ed a ma jo r su b co n t r ac t i s t h e 5 - 2 e n g i n ewhi ch was a GFE ite m . An a t t e m p t h a s b e en made t o i n c l u d e t h e c r i t i c a l mi l e -s t o n e s o f t h e e n g i n e de v e lo p m en t , b u t t h i s was n o t a p a r t o f t h e b a s i ch i s t o r i c a l d a t a i n t h i s s tu dy .

4 . 3 . 2 Major T es t Hardware - The m a j or t e s t h a r d wa r e f o r t h i s p ro gr amwas n o t a s e x t e n s i v e a s t h a t f o r t h e G emini pro gr am . I t c o n s i s t e d o f o neb a t t l e s h i p t a n k , t h r e e s t a t i c t e s t t a n k s , o ne s t a g e mock-up, and on es i m u la t o r , S e ve r al t e s t a r t i c l e s , m o st ly of i n t e r s t a g e and s k i r t s t r u c t u r e ,t h r u s t s t r u c t u r e , a n d mock-ups w er e a l s o u t i l i z e d ,

The b a t t l e s h i p t a n k i s t h e m ost i m p o r t a n t p i e c e o f t e s t h a rd w ar e . I ts u p p or t s t h e e x t e n s i v e t e s t progra m l e a d i n g t o q u a l i f i c a t i o n of t h e s t a g e .The p ri m a r y o b j e c t i v e o f t h e b a t t l e s h i p t e s t p ro gr am was t o p r o vi d e t h e m aj o rd e s i g n p a ra m e te r s of t h e p r o p u ls i o n i n s t a l l a t i o n . The e ng ine mount ing ,p r o pe l l a nt i n l e t l i n e s , b a f f l i n g , p r o p el l a n t fe e d s ys te m, e t c . , we re a l ls i m i l a r t o t h o se on t h e s t a g e . The s ec o nd o b j e c t i v e was t o p r ov e t h e s u i t -a b i l i t y of t h e c o n t r o l and m on i t o ri n g s ys te m s.

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The t e s t pr og ra m was d i v i d e d i n t o two p a r t s : f i r s t , c o l d f l o w o n t h et e s t s t a n d f o r l e a k c he ck s a nd p r o p e l l a n t l o a di n g, an d ,s e co n d, s t a t i c t e s tf i r i n g s o f t h e e n gi n e t o v e r i f y t h e p r o p u ls i o n and i n t e g r a t e d s ys te m s.E l ec t ro m ag n et ic c o m p a t i b i l i t y ch ec ks o f t h e s t a g e - i n s t a l l e d e l e c t r i c a l o re l e c t r o n i c s y st e ms a nd e q u i p m e nt w e re made d u r i n g t h e s e f i r i n g s .

4 . 3 . 3 P l a n s and Sch ed u les - The co ld f l o w t e s t s o n t h e b a t t l e s h i p t e s ts t a n d b e g a n w i t h a s e r i e s o f p r o p e l l a n t l o a d i n g e x e r c i s e s and t a nk p r e s s u r i z a -t i o n t e s t s t o q u a l i fy t h e s up po rt f a c i l i t i e s a nd t o d e ve lo p o p e r a t io n a l p ro ce -d u r e s . T he se t e s t s w er e:

a . L eak and f u n c t i o n a l ch eck sb . Oxid izer sys tem checkoutc . Fu e l sy s t em ch eck o u td . Cold he l ium loa d in g sys tem checkoute . Gaseous hydrogen loa d in g sys tem checkoutf . A mb ient h e l i u m lo a d in g sy s t emg . Loading countdown

A f t e r e n g i n e i n s t a l l a t i o n a n d l e a k c h e c k, a s e r i e s o f " d r yi t c ou nt do wn sl e d t o a " we t" cou ntdo wn w h ich was t e r mi n a t e d j u s t b e f o r e i g n i t i o n . S a t i s f a c -t o r y c o m p le t i on o f t h e s e t e s t s was f o l l o w ed b y l i v e sh akedo wn f i r i n g s . D a taon p r e s s u r e d r o p s i n t h e m ain f u e l and o x i d i z e r l o w -p r es su r e d u c t s we reo b t ai n e d from e a r l y b a t t l e s h i p t e s t i n g , F u e l t a n k a n t i - v o rt e x s c r e e n o p e r a t i o nwas o b s e r ve d d u r i n g d e p l e t i o n t e s t s . S i n c e t h e f u e l t a n k o u t l e t g eo me tr y a ndv o r t e x s c r e e n a r e e s s e n t i a l l y t h e same a s on t h e S-IVY a n i nd uc ed p r o p e l l a n tr o t a t i o n t e s t w as n o t r eq u i r ed f o r t h e S-IVB. The usual pho tography as p r o o f o ft h e s u c c e s s f u l f u n c t i o n o f a n t i - v o r t e x s c r e e n s was n o t r e q u i r e d f o r t h e S-IVB.

F u e l t a n k p r e s s u r i z a t i o n s y s te m t e s t s we re c o nd uc te d t o d e m on s t ra t et h a t t h e g a s e o us hy dr og en b l e e d f ro m t h e e n g i n e co u l d be p r o p e r l y r e g u l a t e d ,and t h a t t h e d i f f u s e r a t t h e t a nk i n l e t was e f f e c t i v e . T h i s i nv ol ve d t e s t ss u c h a s : ( 1) s a t i s f a c t o r y o p e r at i on w i t h l a r g e and s m a ll s t a r t i n g u l l a g e s ,( 2 ) t r a n s i t i o n f ro m g ro und t o e n g in e b l e e d p r e s s u r i z a t i o n , ( 3 ) r e p r e s s u r i z a -t i o n f r om s t a g e h e l iu m p r e s s u r i z a t i o n s y s t em , a n d ( 4 ) p r o p e r f u n c t i o n i n g o ft h e f u e l v e n t s y st em .

S i m i l a r t e s t s o f t h e o x i d i z e r t a n k p r e s s u r i z a t i o n s y st e m w e re c o nd u ct e d.The o x i d i z e r t a n k i s p r e s s u r i z e d f ro m t h e s t a g e h e li u m p r e s s u r i z a t i o n s ys te m.Engine s t a r t t e s t s e s ta b l i s h e d t h e s t a r t pr oc ed ur e an d q u a l i f i e d it f o r

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o p e r a t i o n a l u s e . They a l s o e s t a b l i s h e d p r o p e l l a n t a nd p r e s s u r a n t g a sc on su mp ti on . P r e s s u r e s u r g e s ( w a te r hammer e f f e c t ) i n t h e p r o p e l l a n t f e e ds y st e m when t h e ma in c o n t r o l v a l v e s we r e c l o s e d w er e a l s o i n v e s t i g a t e d . S i nc et h e s t a g e u t i l i z e d a command c o n t r o l c ut - of f r a t h e r t h a n d e p l e t i o n c u t - o f f ,t h i s c o n di t io n was a c r i t i c a l d e si gn s i t u a t i o n . These t e s t s a l s o a id ed i ndeve l op ing s a f e shu t-down sequences . A l l f i r i n g s of t h e b a t t l e s h i p t e s tv e h i c l e w e re mo n i t o red fo r s t a r t and sh ut -d ow n. T h i s p ro v i ded a w ea l t h o fd a t a n eeded t o e s t ab l i s h ru n -t o -ru n and en g in e - to - eng i ne v a r i a t i o n s , and t ov a l i d a t e t h e o p e r a t i o n a l s eq ue nc es .

De ve lopm en t t e s t i n g o f t h e p r o p e l l a n t u t i l i z a t i o n s y s te m was c on du ct eds i mu l ta n e ou s ly w i t h t h e s t a t i c f i r i n g s and f lo w t e s t s . T hese t e s t s en su re dt h a t t h e s ys te m p r o p e rl y s e ns ed i n c i p i e n t d e p l e t i o n i n t h e p r o p e l l a n t t a n k s ,and s a t i s f a c t o r i l y c o n t r o l l e d t h e m i x tu r e r a t i o s u p p li e d t o t h e e ng in e .V a r i o us t y p e s o f s y st e m m a l f u n c t i o n s w er e s i m u l a t ed t o d e m o n s tr a t e t h a t s a f ep r o p u ls i o n s ys te m o p e r a t i o n would c o n t in u e i f p r o p e l l a n t u t i l i z a t i o n s ys te mm a l fu n c ti o n o r f a i l u r e o c c ur r ed .

O th er t e s t s w er e c on du ct ed on t h e s t a t i c t e s t v e h i c l e s , i n cl u di n g t h eu s u a l s t a t i c and dy nam ic t e s t s , p ro of and b u r s t t e s t s o n t a n k s , a nd a f ti n t e r s t a g e p u r ge an d e n v ir o nm e n ta l c o n t r o l t e s t s . An a l l - s ys t e m s t e s tv e h i c l e was a l s o u t i l i z e d . T h i s was a f l i g h t q u a l i t y v e h i c l e used f o r f i n a lc h ec ko u t o f a l l t e s t p r o c ed u re s , f o r s u pp o rt e qu ip me nt i n t e r f a c e s , a nd ,e v e n t u a l l y , a s a dy nam ic s t e s t v e h i c l e f o r t h e S a t ur n V checkou t .

P y r o t e c h n i c t e s t s o f t h e s t ag e s ep a r a t i o n s y st em an d t h e emergencyd e s t r u c t s y st e m w er e c on du ct e d t o q u a l i f y t h e m il d d e t o n a t i n g f u s e e x p l o s i v et r a i n . A ls o, q u a l i f y i n g t h e f ou r r e t r o- r o c k e ts i nc lu de d i n t h e a f t i n t e r s t a g ewas t h e r e s p o n s i b i l i t y of Do ug la s a s t h e s t a g e c o n t r a c t o r . The f i n a l t e s tsch edu le and deve lopment p l an i s shown i n F ig ur e 4-3 .

4 .4 Bas e l i n e P l a n s an d Sch ed u le s - The h i s t o r i c a l d a t a f orm t h e b a s i sf o r t h e b a s e l i n e p l a n s and s c h e du l e s o f t h i s s t u d y. The q u a n t i t i e s o f h ar dw ar eand t h e t i m e p h a si n g s c h e d ul e s d i s c u ss e d b elow r e p r e s e n t e i t h e r t h e a l le x p en d a bl e o r t h e r e u s a b l e e n t r y m odule c o n f i g u r a t i o n s . O t h e r c o n f i g u r a t i o n sa r e c o ns id er e d a s i n c re m e nt a l i n c r e a s e s adde d t o t h e b a s e l i n e q u a n t i t i e s o rt i m e s .

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4 . 4 . 1 Maior Test Hardware - T h e G e m i n i p r o g r a m u t i l i z e d a r e l a t i v e l yl a r g e amount of t e s t ha rd wa re : f i v e b o i l e r p l a t e s , f o u r s t a t i c t e s t e n t r yv e h i c l e s , f o u r s t a t i c a d ap t e rs , a t he rm al q u a l i f i c a t i o n v e h i c l e , and a t l e a s tf i v e t e s t a r t i c l e s a nd s i x mock-ups. A f u t u re development program would n o tr e qu i r e a s many o f t h e m or e e xpe ns ive p ie c e s o f ha r dwa r e, bu t wou ld s t i l l needa t l e a s t t h e amount i t em i z ed i n T a b l e 4-5. The t a b l e a l s o l i s t s t h e a d d i t i o na lamounts needed f o r t h e more advanced conc ept s .

T he se v a r i o u s p i e c e s o f t e s t hardware w i l l b e u s ed t o d e v el o p a nd q u a l i f yt h e p a r a c h u t e o r l a n d i n g s y s t e m ; t o d e v el o p an d q u a l i f y t h e ECS s y s te m ; t od e m o n s t r a te t h e i n t e g r i t y o f t h e c re w m od ul e an d l a u n c h e s ca p e s y s t em d u r i n ga b o r t , w a t e r i m pa ct an d su b se q ue n t f l o t a t i o n ; a nd t o d e m o n st r at e t h e s t a t i c a nddynamic s t r e n g t h c h a r a c t e r i s t i c s of t h e v e h i c l e . I f t h e r e i s a l a r g e i n t e g r a lpro pul s io n sys tem such a s Main Maneuver or Upper S t age Boost , ad di t i on a l ha rdwarei s n e c e s s ar y t o de v el o p and q u a l i f y t h e s y st e m o r s y s te m s . The f i v e o t h e rp r op u ls i on s ys te ms ( r e t r o , o r b i t a t t i t u d e c o n t r ol , e n t r y a t t i t u d e c o n t r o l ,v e r n i e r , a nd l a n d i n g a s s i s t ) t h a t may b e a p a r t o f t h e v e h i c l e a r e d e ve lo p edand q u a l i f ie d u t i l i z i n g t e s t a r t i c l e s o r i n c on ju nc ti on w i th o t h er t e s t snoted above .

The hardware qu a n t i t i e s a r e th e minimums t h a t a deve lopment programwould require . A s t h e a c tu a l p rogr am t o be unde r t a ken be comes ne a r - t er m , t h eamount o f t e s t i n g an d t h e q u a n t i t y of t e s t hardware w i l l be de f ine d byn e g o t i a t i o n b et we en t h e cu st om er a nd t h e c o n t r a c t o r d i r e c t l y i n vo l ve d i np r od u ci n g t h e d e s i r e d v e h i c l e . At s u ch a t i m e , t h e p o l i t i c a l an d f i s c a li n f l u e n c e w i l l s i g n i f i c a n t l y a f f e c t t h e d e g r ee of c o n se r v at i s m w i t h w hi ch t h edevelopment phase w i l l be appr oa c hed . These va l ue s r e p r e s e n t a m idd le - o f- the-r oa d a p p r o ac h , n e i t h e r a s c o n s e r v a t i v e a s p r e v i o us p ro gr am s n o r a s " s p o r t y "a s some t h i n k t h e i n d u s t r y w i l l e v e n t u a l l y e v o l v e .

4 .4 . 2 Subsys tem Pla ns and Schedules - I n d e v e lo p i n g t h e f o l l o w i n gp la ns a nd sc he du le s , c e r t a i n as sum pt ions we re made c onc e r n ing th e na tu r e o ft h e b a s e l i n e s u bs ys te ms f o r t h e v e h i c l e s . The most s i g n i f i c a n t a ss u mp t io nwas t h a t t h e s e new subsys te m s we re new a p p l i c a t io ns o f p r e se n t t e c hno logy .Th i s im p l i e s t h a t de ve lopm en t work i s n ee de d t o a p p l y t h e e x i s t i n g t e c h n o l o g yt o t h e new v e h i c l e r eq u i r e m e nt s , b u t t h a t t h e r e i s no ne ed f o r a m aj o r e f f o r tt o a dv an ce t h e s t a t e - o f - t h e - a r t b e f o r e t h e e f f o r t c a n b e g in . T h i s a ss um est h a t a l l of t he R&D work has been done t o p rovid e a subsys tem which w i l l work

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Table 4-5Hardware Requirements

5 B o i l e r p l a t e s2 - P a r a c h u t e s a n d / o r l a n d i n g s ys t em1 - ECS ev al ua ti on1 - Escape system1 - w a t e r i m p a c t a n d f l o t a t i o n

3 S t a t i c T e s t R ee nt ry V e h i cl e s1 - S t r u c t u r a l T e s t an d A bo rt1 - Dynamic Response and F lo ta t ion1 - P a r a c h u t e Q u a l i f i c a t i o n a n d L an di ng

3 S t a t i c CargoIManeuver Modules1 - S t r u c t u r a l T e s t a nd Q u a l i f i c a t i o n1 - Dynamic Response and Abort1 - P yr o Q u a l i f i c a t i o n

1 Ther m al Qu a l i f i c a t io n ( S t a t i c Ve h ic l e Q ua l i ty Used a s Mock-up)1 C o m p a t i b i l i t y T e s t U n i t1 E l e c t r o n i c S ys te ms T e s t U n i t7 O t he r m aj or t e s t a r t i c l e s ( i . e . , sp eci men h a t c h , p y ro t e s t u n i t s , s t r u c t u r a l

t e s t u n i t s , e t c . )2 Othe r m ajo r m ockups ( Eng ine e r in g a nd P r om ot io na l , a nd tube and c a b l e )

F or I n t e g r a l P r o p u l s i o n ( C o n f i g u r a ti o n C)1 a d d i t i o n a l b o i l e r p l a t e ( f o r t e s t and q u a l i f i c a t i o n of i n t e g r a l pr o pu l si o n)

1 B a t t l e s h i p T e s t V e hi c le1 A d d i t i o n a l B o i l e r p l a t e2 A d d i t i o n a l T e s t A r t i c l e s1 a d d i t io n a l Mock-up

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OPTIMIZED COST/;PERFORbMANCE REPORT NO. G975DESIGN METHODOLOGY 15 APRIL 1969i n a s p a c e c r a f t e nv ir on me nt . S i n c e l an d l a n d i n g i s r e q ui r e d, a l l o f t h e b a s ictechnolo gy deve lopment work t o provid e a workable sys tem i s assumed t o haveb ee n co mp le te d b e f o r e t h e s t a r t of t h e p a r t i c u l a r s p a c e c r a f t p ro gr am . Theo n l y a d d i t i o n a l d ev el op me nt would b e f o r a p p l i c a t i o n of t h i s t e c h no l og y t ot h e new sys tem.

T h es e p l a n s a r e ba s ed u po n t h e MDC e x p e ri e n ce w i t h t h e i d e n t i f i e dsubsystem components. The sched ul e , F i gu re 4-4, i s f o r a r e us a bl e b a l l i s t i ce n t r y v e h i c l e - c o n f i g u r a t i o n I B , w hi ch h a s b e e n assumed a s t h e b a s e l i n e ;however t h e b a s e l i n e v a l u e s a r e a p p l i c a b l e t o c o n f i g u r a t i o n A an d C a l s o .O th er c o n f i g u r a t io n s a r e h an dl ed a s p e r t u r b a t i o n s .

The l a nd ing sys t e m sc h e du l e a ssum es a s a i l w i n g s ys te m. T h i s s y s t em i st h e p a c i nq i t e m , r e q u i r i n g 35 m on th s f ro m go -ahead t o f l i g h t q u a l i f i c a t i o n .A ll ow in g a t h r e e month c o n t i ng e n c y f o r t h e s u bs ys te m c o n t r a c t o r , t h e t o t a lt im e t o a f l i g h t q u a l i f i e d s ys te m i s t h i r t y - e i g h t m o n t h s .

The ECLS sys te m sc he du le a ssume s a c onve n t iona l one- ga s sys t em u t i l i z i n gg a se o us s t o r a g e and l i t h i u m h y d ro x i d e, b a s i c a l l y e x i s t i n g t e c h n o l og y , a n da p p l i c a t i o n .

The gu ida nc e a nd c on t r o l sys t e m i s assumed t o b e e s s e n t i a l l y e x i s t i n g .Im pr ov ed a c c u r a c y f o r t h e l a n d i n g p h a s e i s r e q u i r e d wh ich a f f e c t s b o t h t h ei n e r t i a l r e f e r en c e and t h e c o n t r o l e l e c t r o n i c s .

When i n t e g r a l up p e r s t a g e p r o p u l s i o n i s added t o t h e s p a c e c r a f t , t h i sp r op u l s i on sys t e m bec om es t he pa c ing i t e m . The developme nt t im e f o r th eSa tu rn S-IVB s ta g e was shown pr ev io us ly . I t i s assum ed t h a t t h e m i l e s t o n e si n t h a t p ro gram a r e t y p i c a l o f t h o s e ex pe ct ed f o r t h e i n t e g r a l up pe r s t a g ed e ve l op m en t . H ow ever, a s h o r t e r ti m e f ro m go-ah ead t o i n i t i a t i o n o f t e s tf i r i n g i s e x p e c t e d , I t i s a ss um ed t h a t t h e t im e fr om g o-a he ad t o q u a l i f i c a t i o nwould be about 54 months f o r a b a l l i s t i c v e h i c l e a nd 57 m onths f o r a n M2-F2v e h i c l e .

F o r t h e M2-F2 c o n f i g u r a t i o n s , t h e l a n d i n g s y s t em d ev el op m en t i s s h o r t e r ,a bou t 2 7 months, and i s n o t t h e p a c i n g i t em , H ea t p r o t e c t i o n d ev el op me ntr e q u i r e s c o n s i d er a b ly more e f f o r t , and i n c o n ju n c ti o n w i t h t h e s t r u c t u r a lsubsys tem, i t becomes t h e p a c i n g i t e m a t a b o u t 37 months. The esc ape sys temn o l o n g e r u t i l i z e s a t o w er , b u t t h e d ev el op me nt c a n s t i l l be completed

24MCDBrVrVELb BOCPGkPaS ASTRONACPPSCS COMPANY

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FIGURE 4-4

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C o n f i g u r a t i o n

I A , I B , I CI D , I E , I F

I I A , I I B , I I C

I I D , I I E , I I F

OPTIMIZED CBSThPERFORMANCEDESIGN METHODOLOGY

Table 4-6Subs yste m Development Time

S ub sy st em Q u a l i f i c a t i o nComplete (Months)


Pacing Subsys temLanding System

e r S ta e~ ~ ~ ~ U l S l 0 $S t r u c t u r e / T h e r m a lP r o t e c t i o nUpper StageP r o p u l s i o n

w i t h i n 24 months. T he r ema in in g s u b s y st ems can be d ev e lo p ed w i th in t h e b as e -l i n e v a l u e s shown i n F i g u r e 4-4. A n a l y s i s r e s u l t s a r e s um ma ri ze d i nTable 4-6.

4 .4 . 3 Sp ac ec ra f t System Development - Fig u r e 4-5 p r e s e n t s t h e b a s e l i n edevelopment program f o r a r e u s a b l e modular b a l l i s t i c e n t ry v e h i c l e w i thex p en d ab le mi s s io n mo d ule , co n f i g u r a t i o n I B . T h i s i s a l s o t r u e f o r c o nf ig u ra -t i o n I A and I C . Comparing t h i s f i g u r e and t h e pr e v i o u s f i g u r e i n d i c a t e s t h a tt h e f i r s t manned f l i g h t w i l l o c c u r ab ou t f o u r months a f t e r t h e p a ci ngs u b sy s t em h a s r each ed q u a l i f i c a t i o n . The unmanned d eve lop men t f l i g h t s w ou ldo c cu r j u s t a f t e r t h e s ub sy st em s a r e q u a l i f i e d , and a f i v e - f l i g h t t e s t pro gra mw ould co mp le t e ly q u a l i f y t h e s y st em.

I f t h e v e h i c l e i s a n M2-F2, c o n f i g u r a t i o n I I A , B, o r C , t he f i r s tmanned f l i g h t w ou ld b e d e l a y e d u n t i l a b o u t 4 3 mon th s a f t e r g o- ah ead. T h i s i sd ue t o t h e l o n g e r s u bs y st e m q u a l i f i c a t i o n p ro gr am ( 37 m on th s) a nd t o t h e l o n g e r t i mep e r io d s b e tw een l au n ch es . Al lowing fo ur months be tween th e unmanned f l i g h t andt h e f i r s t m a nn ed -f li gh t, t h e man n ed - f l i g h ts s h o u ld b eg in ab o u t 4 3 mon th s a f t e rg o- ah ead an d s h o u ld b e co mple t e t e n mon th s l a t e r .

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T he d ev el op me nt p ro gr am f o r t h e c o n f i g u r a t i o n s h a v i n g i n t e g r a l u p pe r s t a g ep r o p u l s i o n ( c o n f i g u r a t i o n I D , I E , I F , I I D , I I E , a nd I I F ) w i l l h av e a s i m i l a rf i v e - f l i g h t t e s t pr ogr am . T he se w i l l e x t e n d 1 0 m ont hs o r 1 4 m on th s a f t e rs u b sy s t em q u a l i f i c a t i o n , d e pe n di n g o n w h e t he r a b a l l i s t i c o r M2-F2 v e h i c l e i su n d e r c o n s i d e r a t i o n . T hu s, t h e s e l a r g e r v e h i c l e s w i l l h av e a l o n g e r d ev e l o p -ment t ime ex tend i ng t o abou t 73 months fo r an M2-F2. These t imes a r esummarized i n Table 4-7 and shown i n Figu re 4-6 .

Tab l e 4-7

Development Program Time(Throu gh f i r s t 5 f l i g h t s )

C o n f i g u ra t i o n

I A , I B , I CI D , I E , I FI I A , I I B , I I CI I D , I I E , I I F

Development TimeMonths

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REPORT NO . G97515 APRIL 1969

Figure 4-6


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5. OPERATIONS AND SUPPORT - During Phase I o f t h e s t u d y , s e v e r a lO p e r a t i o n a l an d Su pp o rt A c t i v i t i e s w e re i n v e s t i g a t e d . Those having somei n f l u e n c e upon t h e s p a c e c r a f t r e l a t e d t o t a l c o s t p i c t u r e o f a l o g i s t i c sm i s s i o n we re ( a ) p r e l a u n c h an d l a u n c h o p e r a t i o n s , ( b) t h e l a u n c h s u p p o r ta nd m i s s i o n o p e r a t i o n s , ( c ) r e co v e ry s i t e q u a n t i t i e s an d meth od ofo p e r a t i o n , ( d ) re c ov e ry f o r c e s , a nd ( e ) r e c e r t i f i c a t i o n o r re fu r bi s hm e nt .

The l a un c h o p e r a t i o n s a n a l y s i s r e s u l t e d i n e s t im a t i n g r e l a t i o n s h i p so f man-h our c o s t s t o v e h i c l e s i z e , c o n f i g u r a t i o n , a nd number of l a u n c h e s .T he se o p e r a t io n s r e q u i r e a c t i v i t i e s f o r s u p p or t and m i s s io n c o n t r o lwh ic h a r e f u nc t i on s o f p rogr am du r a t i on a nd number o f l a unc he s . Add i t io na lc o s t a r e a s o f AGE and F a c i l i t y M a in te na nce we r e a l s o a na lyz e d .

R ec ov er y s i t e s and r e c ov e r y f o r c e s e n t e r i n t o t r a d e - o f f s w i t h v e h i c l em an eu ve r c a p a b i l i t y . To p e r m i t t h e s e t r a d e - o f f s t o b e p e rf o rm e d, t h ec o s t s o f o p e r a t i n g o n e o r more r e c o v e r y f o r c e s a n d r e c o v e r y s i t e s w er ed e te r mi n ed . I n a d d i t i o n , a s t a t i s t i c a l a n a l y s i s of s i t e l oc a t io n v s r e t u rnp r o b a b i l i t y w as c on du ct ed t o e n s u r e t h e d a t a o n m aneuver c a p a b i l i t yr e q u i r e m e n t s , d i s c u s s e d i n S e c t i o n 4. 5 of Book 1 was r e a l i s t i c r a t h e rt h a n i d e a l l y p a r a m et r i c.

R e c e r t i f i c a t i o n o r r e fu r b i sh m e n t a n a l y s e s we re p r i m a r i l y b as ed o np r e vi o u s s t u d i e s . The r e s u l t i s a se t of e qua t ion s t o e s t im a te ma n- hour sand f low t i m e a s a f u n c t i o n o f v e h i c l e s i z e , c o n f i g u r a t i o n , a nd su bs ys te m.P r o v i s i o n s t o i n c l u d e o r n o t i n c l u d e t e s t i n g a t t h e combined s y s t em st e s t l e v e l ( co m pl e te v e h i c l e c h ec k ou t ) an d h o t - f i r i n g o f t h e p r o p u l s i o ns y s t em s a r e c o n t a i n e d . T h es e r e s u l t i n g man -ho urs c a n b e e a s i l y c o n v er t e dt o a c o s t t o w hi ch c a n b e add ed t h e m a t e r i a l s c o s t s , t o p ro du ce a t o t a ld o l l a r c o s t f o r r e c e r t i f i c a t i o n .

5 .1 P r e la unc h a nd Launc h Ope r a t ion s - The s p a c e c r a f t l a u n c h o p e r a t i o n sc o n t r a c t f o r t h e G em in i p ro gra m en co mp as se d m ore a c t i v i t i e s t h a n j u s t l a u n c ho p e r a t i o n s a n d l a u n c h s u p p o r t . S u b s t a n t i a l e f f o r t was made i n AGE de s ign a nd


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mo d i f i ca t io n , t r a i n i n g o f grou nd c r ews , f a c i l i t y ch eck o u t and ma inten an ce ,and advanced miss ion p lann ing . T h i s a n a l y s i s r e l i e d h e a v i l y upon t h e w ork o fReference 5-1, bu t inc l uded nea r ly 875 ,000 man-hours charged t o thes e op er a t io nsnot con sider ed th er e . The ad ju s t ed t o t a l man-hours expended on the Capeop er at io ns was 4 ,952,251, in cl ud in g 105,569 man-hours of S t . Louis launc hs u p p o r t e f f o r t .

5 .1 .1 Gemin i Cape A ct iv i t ie s - The co st code it em s of t h e Gemini programd i r e c t l y r e l a t e d t o t h e p r e p a r a t i o n and l au nc h of t h e s p a c e c r a f t grou ped i n t os i x f u nc t io n al l y- o ri e nt e d c a t e g o ri e s . These i n vo l ve i n d u s t r i a l a r e a a c t i v i t i e sw i t h i n t h e main b ui l d i ng s ; t h e i n d u s t r i a l a r e a a c t i v i t i e s a t r em ote l o c a t i o n s ,i . e . p yr o b u i l d up ; on-pad a ss em bl y a c t i v i t i e s ; p re l a u n c h s y st em s t e s t i n g ;f i n a l co un tdow n; a n d m i s c e l la n e o u s a c t i v i t i e s .

S u p po r t- r el a te d a c t i v i t i e s we re ge n e r a l s u p p o r t, m a t e r i a l s and l o g i s t i c ss u p p o r t , o p e r a t i o n s s u p p o r t , p r e - d el i v e r y t e c h n i c a l s u p p o r t , s u b c o n t r a c t o rf i e l d su p p o r t , r e p a i r o f g ov ernmen t owned eq uipment , an d l i a i s o n o r su p p o r te n g i n e er i n g ; a l s o i n c l u de d w er e r e p o r t s and s k e t c h e s , f u t u r e m i s s i o n p l a n n i n g ,and th e l au n ch su p p o r t p ro v id ed by p e r so n n e l co v e red by t h e p ro d u c t io n co n t r ac t .M i ss i on c o n t r o l s u p p o rt a c t i v i t i e s i n cl u de d t h o s e f o r t h e s i m u l a t o r ,c o n t r o l o p e r a t i o n s an d a c t i v i t i e s , and gro und c rew t r a i n i n g .

The l au n ch o p e r a t i o n s c o n t r a c t a l s o i n c l u de d A GE -rela ted a c t i v i t i e s , s u c ha s a d d i t i o n a l AGE d e s i g n and f a b r i c a t i o n , GSE ite m s , AGE s p a r e p a r t proc ure me nt,AGE re se ar ch and development, AGE m o d i f i c a t i o n a nd d e s i g n , f i e l d c h an ge n o t i c e s ,and AGE m a in te na n ce a nd v a l i d a t i o n . T he re a l s o w ere a few a c t i v i t i e s r e l a t e dt o v a l i d a t i o n , m ai nt en an ce , a nd a c t i v a t i o n of f a c i l i t i e s .

There a r e many sm al l va lue co st codes and co st i t e m s i n t h e d e t a i le dbreakdown of t h i s Gemin i Spac ecr af t Opera t ions c on t r ac t t ha t have been combinedi n t o t h e g e n e r al s u p p o r t c a t e go r y. The re cor ds f rom which t h i s d a t a wasex t r ac ted h ad 38 i t em numbers su b d iv id ed in to a t o t a l of 360 co s t co d es .

The de ta i l e d acco unt ing of man-hours cov ers only Gemini 5 th rough 12b ecau se ea r ly i n th e p ro gram a l l o f t h e man-hour ch a rg es were reco rd ed ag a in s t


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o n e co s t n umber. H ow ev er , ab o u t t h e t i me Sp ace c ra f t 5 was d e l i v e r ed t o t h e Capei n d u s t r i a l a r e a , new a cc o u n t in g p r a c t i c e s w er e i n s t i t u t e d w hic h al lo w ed c o s t s t o b et r a c k e d by s p a c e c r a f t .

I n s u p po r t , t h e a c t i v i t y c a l l e d " Re pa ir of G overnment-Owned ~ ~ u i ~ m e n t "as theo n l y a r e a w he re a s i g n i f i c a n t h ar dw ar e c o s t was a s s o c i a t e d w i t h t h e a c t i v i t y . Themanhours e xp en de d o n t h i s a c t i v i t y a pp r ox im a te d 1 79 ,0 00 o r a b o u t 3 . 6 p e r c e n t o f t h et o t a l man ho ur s. A sso c i a t ed was a c o s t of $ 2, 96 6 ,8 95 p a i d t o s u b c o n t r a c t o r s f o rm a t e r i a l s a nd s e r v i c e s . T h i s was a b o u t t w ic e t h e manhour c o s t .

A no th er c o s t i t e m i n t h e S u p po r t c a t eg o r y i s fu t u r e p ro gram p l an n i n g . Th i s w aswork performed f o r NASA which was no t re l a t e d t o t h e Gemini program and co ns is te do f a d va nc e p l a n n in g t e c h n i c a l s u p p o r t t o t h e o f f i c e s w i t h i n t h e Kennedy S p a c e f l i g h tCen t e r . A p p ro x ima t el y 2 8 9,50 0 man ho ur s w e re ch a rg ed t o t h i s , r ep re s en t i n g 5 .8 p e r -c e n t of t h e t o t a l , o r 2 4. 5 p e r c e n t o f t h e s u p p or t c a t e g o r y m an ho ur s.

5 .1 .2 D a ta O rg an i za t i o n - S i n c e t h e h i s t o r i c a l d a t a of t h e G emini S p a c e c r a f tO p e ra t io n s c o n t r a c t was n o t u s e f u l i n i t s b a s i c f or m, t h e f i r s t pr ob le m a t t a c k e d wast h e r e f o r m a ti n g of t h a t d a t a i n t o t h e Co st E le men t S t r u c t u r e p a t t e r n . T h i s in v ol v edr e a r r a n g i n g t h e d a t a of R e f er e nc e 5-1, a dd in g t h e c o s t s e x cl ud ed i n t h a t a n a l y s i s ,v e r i f y i n g t h e j o b d e s c r i p t i o n s f o r e a ch c o s t c od e o r c o s t i te m , a nd c he ck in g t oe ns u re t h a t t h e r e s u l t i n g t o t a l d u p li c at e d t h e t o t a l s f o r t h e c o n t r a c t s in vo lv edas re po r t ed i n th e NASA form 533 re po r t s . There was a 248,000 manhour d i f fe re nc e i nt h e va lu es recor ded i n Refer ence 5 -1 and t hos e de te rmined f rom t h e NASA fo rm 533r e p o r t s . T h i s i s p a r t l y ex p l a i n ed by t h e d i f f e r en t d a t a so u rc e s ; t h e NASA fo rm 53 3r e p o r t s a r e a c t u a l t o t a l s w h i l e t h e s o u r c es f o r R e f e r en c e 5-1 w e re i n c om p l et e , h a vi nga b o u t 97 p e r c e n t o f t h e t o t a l r un - ou t c o s t s b u t n e g l e c t i n g d i v i s i o n a l o ve r h ea d ,g e n e ra l o v e rh ead, an d t r av e l . Th ese upw ard ad j u s t men t s w ere made i n t h e b ro adc a t e g o r y o f S u pp or t s i n c e t h e NASA f or m 5 33 r e p o r t s a r e n o t s u f f i c i e n t l y d e t a i l e d t oi d e n t i f y t h e e x a c t c o s t c a t e go r y t o be a d j u s t e d . The r e s u l t a n t d a t a , r eg ro up e d an da d j u s t e d , a r e p r e s e n te d i n T a b le 5-1. T he se d a t a c o n s t i t u t e t h e b a s e o n w hic h t h ea n a l y s i s w a s p e r fo rmed . The Su p p o r t A c t i v i t i e s i n c l u d e a l l c o s t s c ha rg ed a g a i n s tsp acec ra f t n u mb er 1 through number 4 .

A s ec on d r e o r g a n i z a t i o n r e s u l t e d fr om t h e g u i d e l i n e as s um p ti on t h a t t h e f i r s tf i v e f l i g h t s o f t h e G em ini pr og ra m w ould b e c o n s id e r e d t h e d ev el op me nt f l i g h t t e s tp h ase . D eepe r an a l y s i s o f t h e Gemi ni p ro gram d a t a su g g es t ed t h a t t h e f i r s t unmannedG em ini f l i g h t more c l o s e l y r es em bl ed a s t r u c t u r a l i n t e g r i t y t e s t t h a n a n unmanned

32MCLSOMNELL DOUGLAS ASTRONAUTICS COMPANY

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t e s t f l i g h t . The s t r u c t u r e w as m o s t l y b o i l e r p l a t e , c o n t a i n e d f ew s u b sy s t e m com-p o n e n t s , a n d no a t t e m p t was made t o r e c o v e r t h e v e h i c l e . Thus, we hav e assumed t h a tGemini 2 was t h e f i r s t u n i t , a nd t h a t G emini 6 was t h e l a s t v e h i c l e i n t h e f l i g h tt e s t p r o g r a m . Th i s a g r e e s w i t h t he a c t u a l Ge mini pr og ra m which c ons ide r e d Ge mini 7t h r o ug h G em in i 1 2 a s q u a s i - o p e ra t i o n a l f l i g h t s .

Table 5-1Ac tua l Gem in i Ope r a t io ns a nd S upport C os t s

Launch Opera t ionsI n d u s t r i a l Area A c t i v i t i e sR ad ar C a l i b r a t i o n a n d P yr o B u i ld u pOn-pad Assembly A c t i v i t i e sOn-pad T e s t A c t i v i t i e sCountdownM i s ce l la n eo u s A c t i v i t i e s

M i s s i o n C o n t r o l a nd S u p p o rtM i s s i o n C o n t r o lS u pp or t A c t i v i t i e s

Ad di t i on a l AGEAGE M ai n te na nc eF a c i l i t y A c ti v at i onF a c i l i t y M a i n t e n a n c eT o t a l s

Manhours586,937

The a pp r oa c h fo l lo w e d was t o f i t c u r v e s t o t h e r e c u r r i n g d a t a o f G emin i 5t h ro u gh Gem ini 1 2 ; t o e s t a b l i s h v a l u e s f o r e ac h c at e g o ry ; t o r e a d j u s t t h e S up p or tc a t e g o r y t o t a l s downward by t h e a mo un t c a l c u l a t e d f o r f l i g h t s two t h r o u g h f o u r ; t oe s t a b l i s h a r e c u r r i n g r a t e f o r t ho se c o s t s d e fi ne d on ly i n t o t a l s ; and t h e n t od e t e rm i n e t h e r e l a t i o n s h i p s t o b e u se d i n de ve lo pi ng t h e c o s t m od el .

I n s p e c t i o n of t h e d a t a r ev e a l e d a w id e s c a t t e r e x h i b i t e d by n e a r l y a l l c a t e -g o r i e s . I n a t t e mp t in g t o o b t a i n me an in gf ul r e s u l t s , c e r t a i n d a t a p o i n t s w erei gn or ed i n f i t t i n g c ur ve s t o t h e d a t a . T he se " wi ld p o i n ts 1 ' c a n b e a t t r i b u t e d t o t h ef o l l o w i n g o c c u r r e n c e s :

a . ground equ ipm e nt f a i l u r e sb . s p a c e c r a f t s u bs y st e m m a l f u n c t i o n sc . r e t e s t i n g a f t e r r e p a i r s

33NlCDOAlNELL DOUGLAS ASP-ROAIAUTICS COMPANY

EASTERN D l W l S l Q N


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d . l a u n ch s c r u b s an d r e c y c l e se . "hur ry -upt1 laun chi ngf . w e at h er d e l a y sg . i n c o r r e c t t i m e c h a r gi n g by p e r s o n n e lThe r e s u l t i n g e q u a t i o n s r e c o g n i z e a r e a s o n a b l e amount o f " i n e f f i c i e n t "

a c t i v i t y d ue t o r e w o r k a n d r e t e s t i n g .The r e c u r r i n g d a t a b a s e i s smal l (Gemini 5 through Gemini 1 2 ) a n d e x t r a -

p o l a t i n g t r e n d s bo th t o f i r s t u n i t s a nd t o 50 o r more l a c k s r i g o r . However,i t i s s t i l l r e a so n a b le t o e x p ec t t h e r e s u l t s t o be me an in gf ul a s a p l a nn i ngt o o l . With t h i s i n m in d, t h e d a t a w er e f i t by a " l ea r n in g c u rv e" e q u a t i o n ,

bM = aN , f o r t h e f i r s t 1 0 u n i t s . Beyond t h i s q u a n t i t y , a h y p e rb o l i c o r p a r a b o l i ce q u at i o n was f i t t e d t o t h e s ame d a t a . T h i s was a n a t t em p t t o r ec o g n iz e t h a tt h e r e i s a s i g n i f i c a n t l e a r n i n g r a t e e a r l y i n a program; b u t , a f t e r a c e r t a i np o i n t i n t im e o r i n t h e program, t h i s r a t e g r ad u a l ly d i s ap p e a rs a nd t h e v a l uebecome asym pto t ic t o some co ns ta nt .

5 . 1 . 3 Development of Bas e l i ne Values - The l a u n c h o p e r a t i o n s a nd m i s s i o nc o n t r o l and s u pp o rt a r e d i s c us s e d h e r e . T he se a r e t h e a c t i v i t i e s n or ma ll yco ns id er ed when ETR o r WTR a c t i v i t i e s a r e d i sc us se d .

5 . 1 . 3 . 1 Launc h Ope r a t io ns - The r e c u r r i n g a d j u s t e d d a t a f o r Ge mi ni l a u n c h e s5 t h r o u gh 1 2 was f i t by r e g r e s s i o n a n a l y s i s t o b ot h a " l e a r n i n g c u rv e " a nd ah y p e r b o l i c e q u a t i o n . I n some c a s e s , f ew er t h a n t h e e i g h t d a t a p o i n t s a v a i l a b l ew er e an a ly z ed t o a d j u s t t h e d a t a f o r t h e "w il d p o i n t s " d i s c u s s e d p re v i o u s l y .For e xa mp le, t h e i n i t i a l a n a l y s i s f o r t h e co s t- s ub c at e go r y o f I n d u s t r i a l AreaA c t i v i t i e s i n d i c a t e d t h a t t h e g r e a t e r t h e number of l a un c he s , t h e g r e a t e r wouldb e t h e u n i t c o s t . S i n c e s u ch a c o n c l u s i o n d o es n o t a g r e e w i t h e x p e r i e n c e , ad e e p er a n a l y s i s o f t h i s c o s t d a t a was n e c es s a r y .

The i n d u s t r i a l a r e a a c t i v i t i e s f o r G emini 5 an d 7 we re c o ns i de r a b ly be lowt h e t r e n d o f t h e d a t a . T he se s p a c e c r a f t w e re p r e p a r e d w i t h a minimum of d e l a y ,a n d , i n t h e c a s e of G em in i 7 , u nd er g r e a t u r g en cy t o g e t t h e l a u n ch o f f q u i c k l y .I n c o n t r a s t , f o r Gemini 9 a n unusu a l ly h i gh number o f p r ob lem s du r ing t h ei n d u s t r i a l a r e a a c t i v i t i e s r e q u i r e d e x t e n s i v e r e t e s t i n g and s ome componentr e p l a c e m e n t . B ot h s i t u a t i o n s a r e n on -s ta nd ar d and t h e r e f o r e t h e s e t h r e e d a t ap o i n t s w e re n e g l e c t e d ; a much m or e r e a s o n a b l e " l e a r n i n g c u r v e " e q u a t i o n r e s u l t e d .

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OPTIMIZED COSThPERFORMANCE REPORT NO . G975DESIGN METHODOLOGY 15 APRIL 1969

T h i s i n d i c a t e d a n a p pr o xi m at e l e a r n i n g r a t e of 76 p e r c e n t . A s i m i l a r a ppr oa c hwas f o l l o w ed f o r a n y c o s t s u b c a t e g o r y w he re a n o ma l i es c o u l d b e i d e n t i f i e d b u tn o t q u a n t i f i e d .

Dur ing pa d a s se m bly ope r a t ion s , bo th Ge mini 9 and Gemini 1 2 enco unte redmore t h a n t h e u s u a l number o f d i f f i c u l t i e s . Thi s r an t h e man-hours expendedi n t h i s a c t i v i t y f o r t h e s e two c o ns i de ra bl y a bo ve t h e t r e nd l i n e . A l s o ,t h e r e v e r s e w a s t r u e o f Gem in i 10 wh ic h was n e a r l y a " t e x tbook" ope r a t ion ,F or t h e Pa d A sse mbl y O p e r a t i o n s , t h e d a t a i n d i c a t e d l i t t l e " l e a r n ing" wa sa c t u a l l y e xp er ie nc ed i n t h i s a c t i v i t y . I n i t i a l d a t a a n l a y s is i n di c a t e d as l i g h t n e g a ti v e l e a r n i n g, and t h e a d j u s t e d d a t a i n d i c a t e d a b o ut 98 p e r c e n tl e a r n i n g .

A s ment ioned pr ev io us ly , Gemini 9 was p lagued by problems th roughout t h eCape op er a t io ns . I n On-Pad Tes t i ng , i t r e q u i r e d a b o ut t w i c e as m uc h e f f o r ta s ex p e c t e d , b a s ed o n t h e t r e n d l i n e . D ur in g t h e Countdown A c t i v i t i e s i tr e q u i r e d a b o ut 5 0 p e r c e n t more e f f o r t t h a n e x p e c t e d. I n b o t h of t h e s e c o s ts u b c a t e g o r i e s , G e m i n i 9 d a t a was n e g l e c t e d i n d e ve l o pi n g t h e e q u a t i o n se x p re s s in g t h e t r e n d s .

Gemini 6 and Gemini 10 bot h exp er ien ced smooth countdown op er a t io ns ,a nd w er e c o n s i d e r a b l y b el ow t h e t r e n d l i n e . T h es e p o i n t s w er e n e g l e c t e d i nt h e c u rv e f i t t i n g f o r t h e e q u at i o ns r e p r e s e n t i n g Countdown A c t i v i t i e s .

I n t h e l a s t s u b c a t e g o r y of M i s c e l la n e ou s O p er a ti o n s d a t a f o r G emi ni 5 ,w e r e n e g l e c t e d as a "wi ld po in t " . Both e q ua t io n s w ere f i t t e d t o t h i s l a t t e rc a t e g o ry d a t a s i n c e t h i s p a r t i c u l a r c a t e g o ry was e x p ec te d t o e x p er i e nc e a h i g hi n i t i a l l e a r n i ng r a t e and, a f t e r a modera te number of l aunc hes , approach somen e a r l y c o n s t a n t v a l u e ,

S inc e t he e qu a t i on s de ve lope d we r e ba se d upon Ge mini da ta , i t seemedr e as o n ab l e t o f u r t h e r a d j u s t t h e d ev el op ed e q u at i o ns s o t h a t t h e y w i l l r e pr od u cet h e G emi ni l a u n c h o p e r a t i o n a c t u a l s f o r G em in i 5 t h r ou g h 1 2 . T h i s i n v o l v e sc h ec k in g t h e r e c u r r i n g c o s t s f o r Gemini 5 t h r ou g h 1 2 a g a i n s t t h e estimatesfro m t h e v a r i o u s e q u a t i o n s , a nd a d j u s t i n g t h e c o e f f i c i e n t s o f t h e e q u a t i o n sa c c o r d i n g l y . The r e s u l t i n g man-hour t o t a l s f o r t h e Launch O p e r a t i o n s i s showni n T a b l e 5-2. T h i s r e p r e s e n t s t h e e s t i m a t e d a c t u a l man-hours e xp en de d i n l a u n c ho p e r a t i o n s , b a s e d u po n t h e de v el o pe d e q u a t i o n s .

o p e r a t i o n s , b a s e d up on t h e d e ve lo p ed e q u a t i o n s ,35

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OPTIMIZED CQSThBERFORMANCE REPORT NO. ~ 9 7 5DESIGN METHODOLOGY 15 APR IL 1969

Table 5- 2

Adjusted Gemini Operations and Support Costs

Launch OperationsIndustrial Area ActivitiesRadar Calibration and Pyro BuildupOn-pad Assembly ActivitiesOn-pad Test ActivitiesCountdownMiscellaneous Activities

Mission Control and SupportMission ControlSupport Activities (general)Support Activities (recurring)

Additional AGEAGE MaintenanceFacility ActivationFacility MaintenanceTotals

Manhours724,313

These adjusted equations for launch operations provide a unit man-hourcost for each activity as a function of the specific number of the launch. Ifthese are summed over the total number of launches involved, the total man-hoursfor each activity can be estimated. This total and a labor rate will providea dollar value for each activity.

The resulting basic equations for the launch activity man-hours per launchas a function of the launch number are:

Industrial Area Activities N -. 40044

36MCDONAIELL DOUGLAS ASTHOAIAUTICS COMPANY

EASTERN DIVISION


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VOLUME 1BOOK 2

OPT IM lf ED COSThPERFORMANCEDESIGN METHODOLOGY

Radar Calibration and Pyro Buildup Activities

On-Pad Assembly Activities

All N

On-Pad Test Activities

Countdown Activities

1 < N < 1 0-

Miscellaneous Activities

1 < N < 1 0

REP OR T NO. G9751 5 APR IL 1 9 6 9

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EASTERN DlVUSUON


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OPTIMIZED COSThPERFORMANCE REPORT NO. ~ 9 7 5DESIGN METHODOLOGY 15 APR I L 1969

One a d d i t i o n a l p ro cu re me nt c o s t u s u a l l y a s s o c i a t e d w i t h t h e l a u n c ho p e r a t i o n s i s t h e c o s t of p r o p e l l a n t s an d g a s e s . T he se h a ve b ee n s p e c i f i c a l l ye xc lu d ed f ro m t h i s a n a l y s i s , b u t w i l l b e i n c lu d e d i n t h e c o s t m od ule p o r t i o no f t h e o p t i m i z a t i o n m o de l.

Based upon th e Gemini d a t a , a l l s i x c o s t s u b ca t e go r i es i n d i c a t e d t h a t ar e a so n a b le l e a r n i n g r a t e was e x p er i en c ed i n t h e Cape a c t i v i t i e s . E xc ep t f o rt h e Pad A ssembly A c t i v i t i e s a nd M i s c el l a n eo u s A c t i v i t i e s n o t e d p r e v i o u s l y ,t h i s l e a r n i n g r a t e was i n t h e 75 pe r ce n t t o 80 pe rce nt ran ge . However , a sn o t e d, t h i s h ig h l e a r n i n g r a t e i s e x pe c te d t o d e c r e a s e as t h e number of lau nche si n c r e a s e s . T hu s, t h e l e v e l i n g o u t o f t h e l e a r n i n g r a t e w i l l b eg in a t a bo u tt h e t w e l f t h l au n ch , a nd t h e l e a r n i n g r a t e w i l l b e n e a r l y ze r o by t h e f i f t i e t hl a u n c h. The e q u a t i o n s d e ve l op e d f ro m t h e d a t a r e f l e c t t h i s assu med p a t t e r n .

OPTIMIZED COST Performance Design Methodology

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