BSM Product Assurance Plan Team Briefing

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BSM Product Assurance PlanTeam BriefingPA
plan roll-out

• Ian Pain

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Overview

• The BSM is a high reliability precision cryogenic
  mechanism
• PA plan goal is to provide
• traceability and assurance to the customer
• specific assurance that the product is fit for
  purpose in the space environment.
• the Acceptance Data Package (ADP)
• Reduced cost!

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Quality Assurance at the UK ATC

• UK ATC mission
• be the UK's National Centre for the design and
  production of state of the art astronomical
  technology".
• Quality management (ATC PM procedures)
• ... is the process of ensuring that the quality
  expected by the customer is achieved....All work
  packages must be traceable back to the customer
  requirements to ensure that they are met.
• General ATC practice,
• project engineers responsible for the quality of
  their work
• supervisory aspects covered by the relevant Head
  of Specialism.
• The Chief Engineer is responsible for approving
  the overall quality of the products delivered to
  customers.
• For the SPIRE BSM
• a Product Assurance Manager is designated
• to ensure that the unique quality aspects of
  space flight projects are fully met.

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BSM PA - People
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BSM PA Plan Contents

• ATC QUALITY ASSURANCE
• PROCUREMENT CONTROL
• MANUFACTURING AND ASSEMBLY CONTROL
• NON-CONFORMANCE PROCESS
• PRODUCT ASSURANCE MANAGEMENT
• GENERAL
• DESIGN QUALITY ASSURANCE
• CONFIGURATION MANAGEMENT AND CONTROL
• MATERIAL AND PROCESS SELECTION AND CONTROL
• ELECTRONIC PARTS SELECTION AND CONTROL
• CLEANLINESS AND CONTAMINATION CONTROL
• SOFTWARE PRODUCT ASSURANCE
• RELIABILITY ASSURANCE
• INTEGRATION AND TEST CONTROL
• ACCEPTANCE AND DELIVERY

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Applicability of PA to the BSM models
A Applicable P Partially Applicable N
Non-Applicable
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Key to PA applicability table

• 1. Space rated parts are not required, but
  performance should be equivalent (e.g. Mil-Spec)
• 2. Applied via LAM
• 3. Applicable for components coming into direct
  contact with flight standard hardware (e.g.
  interfacing connectors from GSE cables).
• 4. Applicable to elements directly interfacing
  with the flight hardware, when an impact on the
  flight hardware is possible.
• 5. Applicable to all activities related to design
  verification

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PA plan roll-out

• What
• 2 axis Prototype
• data,
• build,
• fault logging
• Development Model
• Design
• Manufacture
• Assembly
• Test

• When
• starts now
• Why
• it will take us 3 months to get it right
• we need to fine tune the PA plan
• we may want to re-use some DM bits on the STM or
  CQM

• How
• PA reviewed monthly
• Produce all logs etc
• apply as we go.

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Design Documentation
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DESIGN QUALITY ASSURANCE

• PA during design
• Verifying the presence of all necessary inputs,
• Safety and reliability studies,
• The formalization of the functional analysis,
• Verifying interactivity between
  mechanical-electrical and software design,
• Verifying the presence and compliance of "latest
  design" files and documents.
• Controlled documents
• Design Description
• Specification
• ICDs
• PA Plan, Development Plan
• Mechanical Electrical Design Drawings/Models
• Analysis Reports

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Documentation control

• Q-Pulse
• New ATC doc management system
• used on VISTA, SPIRE, others
• ATC SPIRE documents are migrating to it now.
• Will also use it for NCRs
• Intralink
• for models and drawings
• Livelink
• for SPIRE project office consortium files
• Bug-track
• Fault logging during lab work

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MATERIAL AND PROCESS SELECTION AND CONTROL

• Material and process controls implemented
• Space approved materials selected
• Proven cryogenic heritage
• Declared Lists
• Materials
• Parts
• Processes
• .all finalized by the IBDR Nov/Dec.01

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ELECTRONIC PARTS SELECTION AND CONTROL

• Warm Electronics
• Responsibility divided between ATC LAM,
• ATCs bits - Cold Electronics
• Motors,
• Zeiss/PACS
• Sensors
• Infineon (ISOPhot)
• up-screen PAD
• Launch Latch
• LAM/SMEC
• Harness
• approved wiring
• RAL supply?
• In-house solder repair - trained personnel

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Part Approval Document (PAD Sheet)
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RELIABILITY ASSURANCE

• Reliability Block Diagram
• Single Point Failures
• FMEA/FMECA
• Cumulative Operating Time (Log!)
• Environmental Assurance
• Environmental Testing
• Critical Items Identification and Control (Log!)
• may include flex pivots
• may include sensor bonded assemblies

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Procurement Manufacture
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PROCUREMENT CONTROL

• Traceable Purchase Orders (PPARC FMs)
• Supplier Selection
• Incoming Inspection Report
• verification of the packaging conditions
• visual inspection,
• conformance to ordering data,
• certificate of conformance,
• supplier's inspections and control results,
• remaining lifetime (for products with limited
  lifetimes).
• Quarantine Bonded Store
• until released (inspection OK)

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MANUFACTURING AND ASSEMBLY CONTROL

• Manufacturing Request
• Route Card
• Serial Number identification (S/N book)
• Inspection Reports
• Operator Inspection
• Independent Inspection as required
• External attendance at MIP/KIPs if required
• Bonded Store
• Assembly Control Logs

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Manufacturing Documents
Request
Inspection Record
Material Certificates,
Process Records,
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NON-CONFORMANCE PROCESS

• Identify a Non-Conformance
• Quarantine component
• Raise NCR
• NCR review
• Responsible engineer, PA manager others
• Classification (major/minor)
• Disposition
• Report
• Close Out

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NCR management - enter details of CA.
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Non Conformance Report

• Raise using Q-Pulse
• Review
• investigate and close out each NCR,
• recommendation for disposition and corrective
  action
• NCR register reviewed at BSM project meetings,
• NCR review panel
• the responsible engineer identified on the
  Workshop Effort Request,
• the BSM PA manager
• the member of staff raising the NCR.
• Additional staff as required. UK-SPO and/or ESA
  for major NCRs.
• Disposition as
• 'Use as is', with/without requirement for waiver
• 'Re-work or Repair', with attached repair
  instructions.
• 'Scrap'
• Corrective action
• documented and circulated to the relevant HoS.

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Assembly Test
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CLEANLINESS AND CONTAMINATION CONTROL

• Clean Room assembly
• Class 1000 cleanroom
• Class 100 air-bench
• Bakeout
• 80degC
• Transfer from clean room to test dewar
• Limit exposure time
• clean up CCD lab!!
• Bag/purge/cover
• Test Dewar
• cleanliness enforced (semi-clean area)
• Storage
• Dry Nitrogen purge of storage containers

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Cleanliness Certificate
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INTEGRATION AND TEST CONTROL

• Assembly, Integration and Test
• Test Procedures
• Test Witnessing
• Test Reports
• Fault Logging (bug-track)
• Historical Record (Logbook)
• Handling, Storage, Packaging, Marking and
  Labeling, Transportation

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Assembly Log
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Mate/ De-mate Log
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Acceptance data pack

• Shipping Documents
• Procedures for Transport Handling Installation
• Certificate of Conformance/Delivery Review board
  MOM AI Lists
• Qualification Status/Test Matrix
• Top Level Drawings incl... Family Tree
• Interface Drawings
• Functional Diagrams (Block Diagram)
• Electrical Circuit Diagrams
• As built configuration lists
• Serialized Components List
• List of Waivers
• Copies of Waivers
• Operation Manual
• Historical Record
• Logbook/Diary of Events

• Operating Time/Cycle Record
• Connector Mating Record
• Test Record
• Calibration Data record
• Temporary Installation Record
• Open Work / Deferred Work / Open Tests
• List of Non-Conformance reports (NCR's)
• Copies of Non-Conformance reports (NCR's)
• Test Reports
• Mass records / Power Budgets
• Cleanliness Statement
• Compliance Matrix
• Photographs

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PA Plan Summary

• PA Plan Goal Fitness for purpose
• Purpose
• Reliable cryogenic high precision mechanism
• Space qualified
• Integrated to a 10M instrument
• Method
• Rigorous Design
• Configuration Control
• Traceable Materials, Parts, Documents
• Fully documented clean room assembly
• Non-conformances design changes, raised
  tracked
• Qualification Programme backs the design
• ADP demonstrated fitness for purpose