Office of Systems Safety and Mission Assurance

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Government-Industry Data Exchange Program
GIDEP as a Resource
Presentation for the GSFC Systems Engineering
Seminar, July 13, 2004
Presented by Michael J. Sampson, Alert
Coordinator Manager, Workmanship and EEE Parts
Assurance NASA GSFC, Greenbelt, MD 20771 Code
306, Systems Management Office, Phone
301-286-3335 Fax [phone] Michael.J.Sampson_at_
nasa.gov
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Overview

• Introduction to the Government-Industry Data
  Exchange Program (GIDEP)
• Charter, Policy, History, Participation and
  Website
• NASA and GSFC involvement
• GIDEP Document Types
• Including Examples
• NASA and GSFC Processes for Handling GIDEP
• NASA Advisories, differences from GIDEP
• GIDEP and NASA Advisories as Lessons Learned
  Tools
• Conclusions

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GIDEP Mission Statement

The mission of the Government-Industry Data
Exchange Program is to support government systems
readiness, productivity and cost reduction
through timely retrieval, storage and
distribution of data among government and
industry organizations. Charter statement
by the Department of Defense Joint Logistics
Commanders
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Office of Management and Budget
Policy Letter No. 91-3 Reporting Nonconforming
Products 4. Policy. Agencies shall review
existing programs or, where necessary, establish
new programs to assure the quality of purchased
products and materials. Information shall be
exchanged among agencies about nonconforming
products. The existing Government/Industry Data
Exchange Program (GIDEP) operated by the
Department of Defense will serve as the central
data base for receiving and disseminating
information about such products.
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GIDEP History

• 1958 Army, Navy, Air Force Team
  established. Ballistic missile engineering
  data.
• 1965-1966 NASA and Canada joined. Alerts
  introduced.
• JLC Adopted Program and sponsorship.
  Naval Warfare Assessment Division lead.
• OMB Policy Letter 91-3. Major Federal
  Agencies join.
• On-line system introduced. Electronic
  distribution.
• 1996 World-wide web access.
• 1996 MIL-STD-1556B CANCELED! Established
  REQUIREMENTS for contractor participation
  in GIDEP. MIL-HDBK-965 is replacement but
  only offers Guidance

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GIDEP Community
GIDEP is a partnership between Government
Agencies and Industry teamed to share
technically valid, fact-based information. The
GIDEP community consists of approximately 400
Government and 1200 Industry Participants.
Scientific and technical information is shared
through an on-line web-enabled database.
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GIDEP Sponsoring Agencies

• US Army
• US Navy
• US Air Force
• NASA
• Department of Energy
• Defense Contract Management Agency
• Canadian Department of National Defence
• Defense Logistics Agency

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http//www.gidep.org
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GIDEP ReportingHierarchy at GSFC
OSSMA DIRECTOR
W. Denoon
Deputy Systems Management R. Day
Code 306 Chief W. Connley
Alert Coordinator M. Sampson
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NASA Documentation

• NPR 8735.1A Procedures for Exchanging Parts,
  Materials, and Safety Problem Data Utilizing the
  Government-Industry Data Exchange Program and
  NASA Advisories.
• Requires ALL NASA Centers Participate in GIDEP
• AND Have a Process to Issue NASA Advisories
• GPG 5340.3D Preparation and Handling of Alerts,
  Safe-Alerts and Advisories.

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GIDEP Document TypesAlerts
Alert A GIDEP document that reports a problem
with parts, components, materials,
specifications, software, manufacturing
processes, or test equipmentthat can cause a
functional failure. Examples

• Cleanroom Wipes Contaminated With Silicones
  (September, 2003) The GSFC issued this Alert
  after receiving cleanroom wipes contaminated with
  silicones. At least one other government agency
  reported contaminated wipes from the same source.
  The responsible manufacturer reported that their
  supplier had provided contaminated raw material.
• Semiconductor Device, Transistor, PNP, Silicon,
  Switching (May, 2004) A transistor exhibited an
  emitter-collector short due to a nickel particle.
  

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GIDEP Document TypesSafe Alerts
Safe-Alert A GIDEP document that reports a
non-conforming item, product or situation that
creates a safety hazard for personnel or
equipment.Examples

• Dynamometer (October, 2004) Dillon alerted
  customers that the Model AN and ANC dynamometers
  (used in overhead lifting) had a safety issue
  associated with fatigue life for units
  manufactured prior to and including 1978. Note
  A total of seven affected dynamometers were found
  at GSFC/WFF and disposed of.
• Stackable Side Chairs, Weld Failure (February,
  2003) Two stackable metal frame chairs failed at
  the weld joint while personnel were sitting on
  them.

For safety issues, contact Terry Spagnuolo (Code
250) Also, for safety issues involving
non-conforming items, contact Mike Sampson (Code
306)
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GIDEP Document TypesSafe Alerts
Problem Advisory A GIDEP document that reports a
problem with parts,components, materials,
manufacturing processes, specifications,
software, manufacturing processes, or test
equipment that has an unknown or low probability
of causing problems for other users. Examples

• Zinc Whisker-Induced Failures of Electronic
  Systems (August, 2003) GSFC originated this
  Advisory with a special emphasis on facilities
  employing raised access floor systems comprised
  of zinc-plated floor tiles and or using a
  zinc-plated steel infrastructure.
• Microcircuit, Hybrid, DC/DC Converter (August,
  2003) The GSFC persuaded an OEM to issue an
  Advisory on a DC/DC converter that failed during
  GSFC ground testing in a vacuum environment. The
  failure was attributable to a solder joint.

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2003 - NASA GSFC Produced GIDEP ZINC Whiskers on
Raised Floor Structures
Zinc-Plated Steel Underside of Floor Tile
Its Growing ZINC WHISKERS!! Estimate 1 - 10
MILLION Whiskers on this Single Tile (4 sq ft
area)
Typical Raised Floor Computer Room
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A Mechanism for Distribution of ZINC WHISKERS
Throughout Raised Floor Facilities
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GIDEP Document TypesAgency Action Notice
Agency Action Notice A GIDEP document that
redistributes problem informationissued by a
Government Agency to GIDEP participants. Examples

• CPSC, Central Sprinkler Company Update Voluntary
  Recall to Replace O-Ring Fire Sprinklers (May,
  2003) The GSFC facilities group is in the
  process of replacing over 3,000 affected
  sprinkler heads that were found on Center.
• Cylinder, Carbon Dioxide (January, 2002) The
  Defense Supply Center Philadelphia issued an
  alert against a manufacturer for defective carbon
  dioxide cylinders used on inflatable life vests
  and life rafts. Wallops found a total of 80
  affected life vest cylinders and removed them
  from service.

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GIDEP Document TypesMetrology Data
Metrology Data Consists of calibration
procedures and technical manuals for various
types of electronic/mechanical equipment.
Calibration procedures provide instructions and
information that enable calibration personnel to
verify that instrument being calibrated is
within prescribed tolerances. Technical manuals
provide detailed maintenance, and/or
repair/operating instructions. Examples

• The ICESat GLAS project requested and received a
  calibration procedure for a torque gauge

GIDEP provides us with FAST access to Calibration
and Tech Manuals that may otherwise be difficult
to obtain.
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GIDEP Document TypesDMSMS
Data on Diminishing Manufacturing Sources and
Material Shortages (DMSMS) Manufacturer data
that provides occurrences of product and or
product line discontinuances. Examples

• CZEM Switzerland Discontinuance of Titanium
  Carbide Coating, Stainless Steel Balls Used in
  Precision Extreme Environment Ball Bearings Two
  companies have partnered to purchase the process
  technology and transfer the equipment to the
  United States.
• Aeroflex Laboratories Notification to the
  Defense Supply Center and all customers that 11
  SMD (5962) part numbers will be discontinued
• Intel Product Discontinuance Notification
  103986-00 Intel is announcing the discontinuance
  of Intel GDLXT12101. Product is discontinued from
  outsourced vendor (UMC). Final order date is
  June 30, 2005

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GIDEP Document TypesEngineering Reports
Engineering Reports are technical papers on a
variety of topics. Examples

• TRWs Broadband Satellite Communication Payloads
  at C and KU Frequency Bands
• Digital Signal Processing for Deep Space
  Transponders
• Animation of Recorded Flight Data
• Assessing the Risks of Commercial-Off-The Shelf
  Applications
• Quick Prototyping of Flip Chip Assembly with MEMS
• On-Chip 3D Air Core Micro-Inductor for
  High-Frequency Applications
• Conformal coatings for 3D Multichip Microsystem
  Encapsulation

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GIDEP Document TypesReliability-Maintainability
Reports
Reliability-Maintainability Reports are
reliability-oriented technical papers on a
variety of topics. Examples

• COTS Ceramic Chip Capacitors An Evaluation of
  the Parts and Assurance Methodologies
• Authored by Jay Brusse (QSS) at GSFC
• Quality Control and Processing of Historical
  Oceanographic Temperature, Salinity, and Oxygen
  Data
• Best Practice Reliability and Maintainability
  Standard
• Best Practice Statistical Quality Control
• Commercial Off-The-Shelf (COTS) Avionics Software
  Study

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GIDEP Document TypesUrgent Data Requests
Urgent Data Requests (UDRs) allow GIDEP
participants to query information from the GIDEP
Community. UDRs are often used to locate surplus
parts that have been discontinued or locate
parts that are critically needed for a given
project. In addition, UDRs are used to solicit
information such as failure data on EEE and
mechanical parts. Examples

• Failure Rate, Failure Experience for Parts in TO
  Packages Assembled with 100 Nickel Caps.
  Failure mode is shorts caused by nickel flake
  particles.
• Failure experience with wirewound resistors.
  Failure mode is intermittent or catastrophic open
  due to weld failure or related wire breakage
• Source of Supply Request for CPU Module
• Failure Experience, Failure Mode for Transistor

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GIDEP Document TypesProduct Change Notices
Product Change and Product Information Notices
provide respective data on product changes (i.e.
datasheet, facility relocations) and product
information (i.e. test data, Qualified
Manufacturer List status, and package types).
Examples

• Micron Product Change Notification PCN1436-PPS2K
  To announce the minimum number of packaged parts
  shipped on a tape-and-reel carrier will change
  from 1,000 devices to 2,000 devices.
• Xilinx Advanced Product Change Notification
  PCN2003-04 Additional wafer fabrication facility
  for the C-grade members of the XC18V00 family of
  the In-System Programmable Configuration PROMs.

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GIDEP Document TypesLesson Learned Bulletins
Lessons Learned provide work experiences on a
variety of subject matter. Sharing adverse
experiences may help avoid recurrences. Examples

• Warning Hotels Could Be Hazardous To Your Health
• Graduate Student Incurs Laser Injury to Eyes
• Damage to Overhead Power Lines by 90-Ton Crane
• Failure of the Finnigan Triton Mass Spectrometer
• Zinc Whisker Shorting in Vacuum

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Warning Hotels Could Be Hazardous To Your Health

• You open the door to your hotel room and drop
  your luggage. AT THAT VERY MOMENT, turn around
  and go back into the hallway to check your
  exit!!! Talk it over as you walk toward it. Is
  it on the left or right do you have to turn a
  corner? Open the exit door what do you see
  stairs or another door? Count the number of
  rooms/doors you go by to get to the exit! As you
  arrive back to your room, take a look once more.
  Do you think you could get to the exit with a
  blindfold on? You better be able to, because
  smoke is a deadly blindfold!!! During a fire, a
  well planned exit strategy can save your life!
• The procedure takes less than one minute to be
  effective. It must become a habit!!!! Those of
  you who are too lazy or tired to do it are real
  riverboat gamblers. There are over 5,000 hotel
  fires per year. The odds are sure to catch up
  with you.
• You must know how to avoid smoke and panic to
  survive a hotel fire!!!

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Access to GIDEP Documents
Due to ITAR restrictions, you must be a US
citizen in order to be granted database
accessibility

• Currently, GIDEP documents can be viewed either
  by
• Registering as a GIDEP User in order to access
  the GIDEP database. See the Alert Coordinator
  for form.
• Subscribing to the OSSMA GIDEP Alert/NASA
  Advisory distribution system. Contact the Alert
  Coordinator in order to be placed on email list.

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GIDEP Distribution Restrictions

• Per the GIDEP Manual, Information distributed by
  GIDEP contains technical data whose export is
  restricted by Arms Export Act (Title 22, USC Sec.
  2751 EtSeq) or Executive Order 12470.
• In addition, GIDEP documents have the following
  distribution restriction Distribution is not
  authorized outside of the GIDEP participants
  organization.

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Incoming GIDEP Document Process

• Per NPR and GPG requirements, an engineering
  review of the following documents is performed
  Alerts, Safe-Alerts, Problem Advisories, and
  Agency Action Notices. In addition, NASA
  Advisories are reviewed.
• Based on review, the documents are distributed as
  appropriate.
• Project (or affected Code) responses are required
  and documented in GSFC closed loop system

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Log of Incoming Alerts and Advisories (Sample
Only)
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Project Summary Metrics
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Creating GIDEP Alerts andNASA Advisories

• Candidates for GIDEP Alerts and NASA Advisories
  are reviewed by the Office of the Alert
  Coordinator
• NASA Advisory A NASA document for exchanging
  significant parts, materials, and safety problems
  or concerns among NASA activities
• Used for NASA-specific and NASA-caused errors and
  lessons learned
• Or when a GIDEP is not possible or practical
• Or to address spaceflight specific implications
  of others experiences
• The Office of the Alert Coordinator provides
  technical writing and content support to the
  Technical Point of Contact
• The Chief Counsel reviews all NASA Advisories for
  legal issues and for unrestricted distribution

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Examples of GSFC NASA Advisories in 2004

• NA-GSFC-2004-08 Testing of Actel SX-A and RTSX-S
  Programming Algorithms
• NA-GSFC-2004-07 Thruster (1.0 lbf) Assembly
  Failure
• NA-GSFC-2004-06 Actel RTSX-S and SX-A Programmed
  Antifuses
• NA-GSFC-2004-05 Cable Failure Attributable to
  Workmanship Error During Assembly of COTS
  Connector
• NA-GSFC-2004-04 TRST and the IEEE JTAG 1149.1
  Interface. FPGAs
• NA-GSFC-2004-03 Unauthorized Distributors
• NA-GSFC-2004-02 Application Concerns on COTS
  MOSFETS from International Rectifier
• NA-GSFC-2004-01 Indium Solder Encapsulating Gold
  Bonding Wire Leads to Fragile Gold-Indium
  Compounds and an Unreliable Condition that
  Results in Wire Interconnection Rupture

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Indium Gold Compounds on GLAS Diode Array
From NASA Advisory NA-GSFC-2004-01
Gold Wire Becomes Fragile And May Rupture
Indium Solder Gold Wires Reliability
Hazard!!!
Indium Gold Intermetallic
Gold Wire
Lesson Avoid use of Indium in Proximity to Gold
!!!
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Lessons Learned

• Alerts and Advisories are VERY Effective Methods
  for Communicating Lessons Learned
• Disposition is Usually Contractually Imposed
• Most Contractors are Long-Time Participants and
  Have Well-Developed Response Processes
• Market Recognition
• Well-Developed NASA Closed Loop Process

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In conclusion, GIDEP is a Resource

• Alerts, Safe-Alerts, Advisories, and Agency
  Action Notices are free.These documents are very
  helpful in ensuring mission success
• GSFC NASA Advisories are freely distributed with
  no distribution restrictions. GSFC NASA
  Advisories capture valuable Lessons Learned
• Obtain free calibration reports to maintain
  equipment calibration
• Engineering and Reliability-Maintainability
  reports are available
• Utilize Urgent Data Requests to locate surplus
  parts and materials
• Urgent Data Requests also can be used to request
  failure experience data
• Free reports are also available on Lessons
  Learned, DMSMS, and Product Change and Product
  Information Notices

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The Alert Process is Two-Way

• Almost Every Project in NASA Will Benefit from
  the Information Provided by GIDEP Documents and
  NASA Advisories
• We Have A Legal and Ethical Requirement to
  Contribute Our Lessons Learned
• So Please Do Your Part and Report Candidate
  Incidents or Experiences
• We Will Make it Easy