10/14/ :25:29 PM ISSP On-Orbit QA To share with QLF the ISS approach to the On-Orbit Quality Assurance process and the current status NASA QLF R. Wang ISS QA

Pg. 2 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA Background - Space Station has been experiencing on-orbit hardware maintenance and upgrade activities, some affecting hardware and system configuration changes. Proper implementation of QA process early will provide confidence of Space Station hardware integrity, system and hardware configuration management verification and tracking, efficiency in the operations, mission assurance, and ultimately enhance the life of the Space Station. Approach - Evaluate current SSP Rev A requirements for on-orbit applicability. Specific new paragraphs to be added to SSP for clarification of its applications to on-orbit ISS. Status: CR 6508 in the ISSP change process. - Develop On-Orbit QA Handbook to provide Program wide guidelines and define processes for the implementation of the QA requirements. Status: draft document has been through several internal ISS S&MA iterations, and is currently being updated for external review and comment.

Pg. 3 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - OCWG OCWG process – SSP baseline version released on Defines Pre-Mission, Mission, Post-Mission/Stage configuration issue identification & resolution processes The OCWG is responsible for identifying and facilitating the resolution of on-orbit configuration issues. The primary responsibilities of the OCWG in regard to ISS on-orbit configuration issues include: - Review and analyze drawing requirements, procedural and format issues for further disposition or recommendation to the program for resolution. - Establish standards for usage of processes and procedures that affect hardware configuration status accounting - Review Configuration Discrepancy Reports (CDRs) to determine need for further evaluation and disposition of specific hardware configuration issues via the IFI/ PRACA process. The OCWG works those issues related, but not limited to, on-orbit traceability issues, on- orbit TCTI/Mod Kit installations or activities, SPRT interfaces, and those processes that support maintaining on-orbit configuration. The OCWG is not intended to address on- orbit configuration discrepancies such as drawing errors, differences between drawings and crew procedures, etc., that can be resolved through the normal CSA process.

Pg. 4 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews On-Orbit Quality Management Approach Management of ISS on-orbit quality assurance implementation includes defining the major QA and SQA tasks to be performed by ground personnel and the on-orbit crew during planning and operations phases to ensure a multi-phased implementation. Quality tasks are not limited to only those tasks that are assigned to QA. ISS on-orbit quality activities and processes for the on-orbit ISS vehicle and operations are the responsibility of ALL ISS organizations. On-Orbit Planning On-orbit quality assurance is to be considered in the development of on-orbit planning and procedures. On-orbit planning is basically how ISS goals, objectives, and priorities are implemented and achieved. On-orbit planning encompasses baseline tasks, expected training and logistics, changing priorities, on-orbit anomalies, and lessons learned. As the dynamic elements are included in the on-orbit planning, attention to quality provides assurance that basic mission objectives can be safely reached. ALL ISS organizations associated with the ISS on-orbit-planning process are responsible for ensuring that quality assurance is maintained throughout the planning process.

Pg. 5 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews On-orbit identification and traceability Hardware and material traceability for the on-orbit ISS is extremely important with respect to maintaining the hardware configuration required per SSP and the stowage requirements described in SSP ISS Engineering and MOD are responsible for knowing the configuration of the on- orbit vehicle for sustaining and operations support. L&M is responsible for knowing the on-orbit configuration with respect to preventive maintenance (PM) and orbital sparing. Configuration Management (CM) is responsible for tracking the “as- designed” engineering baseline versus the “as-built” on-orbit vehicle. QA is responsible for tracking and ensuring proper resolution of on-orbit configuration nonconformances. On-Orbit Operations Data and Information Collection It is necessary to protect the integrity of on-orbit data for historical purposes. On- orbit historical data, telemetry, and Mission Control Center Logs and Shift/Daily Reports are considered quality records. This is required for many reasons. The primary reasons are as follows: maintaining on-orbit configuration of the hardware/software; anomaly resolution; and record evidence for an investigation subsequent to a catastrophic event. MOD is responsible for storing and maintaining all ISS telemetry information downlinked to the ground. All organizations that support the on-orbit ISS vehicle from the MCC generate shift/daily reports and maintain console logs. S&MA is responsible for collecting and processing information per the requirements of SSP Acceptance Data Packages (ADPs).

Pg. 6 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews On-Orbit Operation Controls These controls are intended to ensure the inclusion of information in any flight operations procedure document and includes, as a minimum: Identifying critical characteristics and ensuring that they are adequately addressed as inspection/verification points in procedures, Identifying articles having characteristics of quality degradation or drift with age and/or maintaining data documenting the status of those characteristics. Tracking of temporarily installed/removed hardware. Tracking of maintenance and/or modification performed on the on-orbit ISS to provide a configuration baseline for maintaining the status accounting of delivered hardware. Any organization involved in the development and review of ISS flight operations procedures are required to ensure that the minimum information requirements described in the handbook are met. S&MA, Engineering, and MOD are responsible for selecting critical characteristics derived from drawings, specifications, Failure Modes and Effects Analysis/Critical Items List (FMEA/CIL), Hazard Analysis, etc. L&M is responsible for maintaining as quality records the status of those articles having characteristics of quality degradation or drift with age and/or use. S&MA is responsible for the tracking of temporary installations and removals. S&MA provides verification of on-orbit installation and/or modification information to Configuration Management (CM) to assist in on-orbit configuration status accounting.

Pg. 7 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews On-Orbit Test Operations To ensure the minimum applicable information is included in on-orbit test procedures. This includes the quality requirements that must be met prior to, during, and after testing on the ISS vehicle. Any organization involved in the development and review of ISS on-orbit test procedures is responsible to ensure that the minimum information requirements described in the handbook are met. Control Of Nonconforming Articles and Materials On-orbit nonconformances must be identified and tracked in a closed-loop nonconformance system. Nonconforming hardware is to be identified and segregated by physical tagging (red tag), when practical. Hardware with outstanding functional certification issues is also identified and tagged on-orbit (yellow tag). All suspected on-orbit nonconformances are initially documented and screened through the MER problem evaluation process, and documented in the ISS PRACA per SSP S&MA MER console is responsible for red tagging on-orbit nonconforming hardware. ISSPO “Governing Boards” (e.g., VCB, GCB, ASCB, PICB, EVA CCB, etc) are responsible for initiating a yellow tag for on-orbit hardware with certification issues.

Pg. 8 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews Disposition Of Nonconforming Articles and Materials An on-orbit nonconformance is initially identified and investigated by the ISS MER and documented as an Items For Investigation (IFI). PRACA/SPR is generated as soon as the problem is isolated to the hardware/software. ISS PRACA is used as the nonconformance reporting system for on- orbit problems. PPS MRB process defined in SSP is employed in the on-orbit nonconformance resolution. On-Orbit Quality Training Provide inputs to crew training with respect to workmanship and special processes. S&MA (NASA QA/OE) is expected to review the ISS on-orbit training program and provide the appropriate inputs regarding workmanship and special processes.

Pg. 9 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA - Overviews On-Orbit Metrology SSP requires that a documented metrology tracking system is in place to ensure that measurement standards and calibrated equipment will perform as specified for any on-orbit assembly, installation, testing, or maintenance task. Metrology control is under the JSC Measurements and Calibration Laboratory (MSCL). L&M is responsible for tracking measurement standards and calibrated tools/equipment stowed on-orbit. S&MA Operations is responsible for ensuring that metrology control is enforced and provide independent verification of that on-orbit installations, tests, and other tasks that require measurement standards or calibrated equipment are accomplished per requirements. On-Orbit Preventive Maintenance SSP requires that a documented preventive maintenance tracking system is in place to ensure that on-orbit inspection, servicing, or replacements are performed as required. These tasks are published in the applicable Increment Definition Requirements Document (IDRD) Annex 2. L&M is responsible for identifying and tracking scheduled preventive maintenance activities on-orbit. S&MA Operations is responsible for ensuring that PM activities are being enforced for the hardware and equipment located on-orbit by providing independent verification of scheduled preventive maintenance (PM) activities.

Pg. 10 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA – What we learned We have learned, as should have expected, that the existing processes employed in the operations of ISS vehicle already have the majority of areas covered. The on-orbit QA development process brought attention to some areas that need improvements or process developed Possibly will be identified due to need anyway at some later date The On-Orbit QA Handbook focuses on those areas that do not have existing process and those need improvements SSP Revision B and the identified implementation tasks are determined to be in-scope to Boeing with one exception Collecting and updating ADP from On-Orbit modification or upgrade activities – Difference is being investigated

Pg. 11 On-Orbit QA – QLF 09/24/2002 ISSP On-Orbit QA – Forward Work Complete SSP 50646, On-Orbit Quality Assurance Handbook ECD for the next draft – End of September Provide review copies to organizations external to S&MA that are impacted (MOD, L&M, CM, OB, OD, etc) and begin coordination for comment and agreement Submit for ISSP baseline release and implementation Provide final draft to IP/P for review and negotiation Conduct implementation survey and update SSP if necessary