2. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 1 BSM Product Assurance Plan Team Briefing & PA plan roll-out Ian Pain

3. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 2 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!

4. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 3 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.

5. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 4 BSM PA - People

6. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 5 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

7. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 6 Applicability of PA to the BSM models A = Applicable; P= Partially Applicable; N = Non-Applicable

8. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 7 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

9. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 8 PA plan roll-out 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 What: –2 axis Prototype data, build, fault logging –Development Model Design Manufacture Assembly Test How: –PA reviewed monthly –Produce all logs etc –apply as we go….

10. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 9 Design & Documentation

11. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 10 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 –ICD’s –PA Plan, Development Plan –Mechanical & Electrical Design Drawings/Models –Analysis Reports

12. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 11 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 NCR’s … Intralink –for models and drawings Livelink –for SPIRE project office & consortium files Bug-track –Fault logging during lab work

13. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 12

14. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 13

15. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 14

16. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 15 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

17. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 16 ELECTRONIC PARTS SELECTION AND CONTROL Warm Electronics: –Responsibility divided between ATC & LAM, ATC’s 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

18. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 17 Part Approval Document (PAD Sheet)

19. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 18 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

20. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 19 Procurement & Manufacture

21. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 20 PROCUREMENT CONTROL Traceable Purchase Orders (PPARC FM’s) 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)

22. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 21 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

23. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 22 Manufacturing Documents Request Inspection Record Material Certificates, Process Records,

24. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 23 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

25. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 24 NCR management - enter details of CA.

26. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 25 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 NCR’s. 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.

27. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 26 Assembly & Test

28. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 27 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

29. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 28 Cleanliness Certificate

30. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 29 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

31. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 30 Assembly Log

32. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 31 Mate/ De-mate Log

33. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 32 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

34. 01.Oct.01 SPIRE BSM Product Assurance Team Briefing 33 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