1. The Human Element in Unmaintainable Systems
Lynda A. Bottos
2018 SAE Aerospace Summit
October 2, 2018

2. The Human Element in Unmaintainable Systems
Human Impact Before System Operation
Introducing human error into the supply chain, which leads to latent failures (unintentional).
Creating unconventional* designs, software, methods, processes, or other requirements (intentional).
* Unconventional is not the same as innovative.
The Human Element in Unmaintainable Systems

3. The Human Element in Unmaintainable Systems
Example - Hubble Space Telescope
Spherical aberration of the mirror (wrong shape)
Original launch date in 1986.
Challenger mishap grounded orbiter fleet; had down-time to concentrate on configuration management. Instead, worked on system upgrades.
Launched April 24, 1990 (STS-31); sent back blurry images.
Repaired during the first planned servicing mission in December 1993 (STS- 61); employed a “workaround” using corrective mirrors to focus the image.
The Human Element in Unmaintainable Systems

4. The Human Element in Unmaintainable Systems
Ideas for Preventing Latent Failures
Identify the potential hazards associated with latent failures
Conduct a comprehensive failure mode analysis that includes human error
Accept that errors will occur. No amount of training will prevent errors.
Conduct quality assurance and quality control of the “System,” not “system”
Ensure that processes are accurate and understandable
Reflect the production or maintenance required
Are written in “plain language”
Ensure that software exhibits standardized, conventional coding that any skilled successor can understand, maintain, and upgrade.
Verify vehicle or product through testing when possible.
The Human Element in Unmaintainable Systems

5. The Human Element in Unmaintainable Systems
Example - Future Imagery Architecture (FIA) Satellite Program
Too many unconventional approaches
Lack of seasoned technical staff oversight on the project
Unrealistically low budget for new technology contract (no budget for research/testing)
Budget was $5 billion;
Final project cost nearly $18 billion, and was never delivered
Unrealistic optical design, of could not be built
Use of known non-aerospace rated material by parts suppliers to keep costs down (tin)
The Human Element in Unmaintainable Systems

6. The Human Element in Unmaintainable Systems
Managing the Unconventional Approach
Ensure correct skill mix
Train staff to avoid “creative” designs or coding because they don’t know better
Maintain staff currency for latest techniques, designs, codes, etc.
Eliminate staff single-point failures
Assign back-ups; they should be as skilled as the primaries
COR *- Contracts need technical oversight, not just administrative oversight
*Government Federal Acquisition Regulations (FARs) eliminated the Technical Operations Representative (TOR). Most Contracting Representatives (CORs) do not have the expertise to both manage the day-to- day contract activities and technically evaluate deliverables. Ensure contracts have a dedicated technical SME who can help accept the deliverables.
The Human Element in Unmaintainable Systems

7. The Human Element in Unmaintainable Systems
Main Take-Aways
Humans will make errors.
Tolerating is better than mitigating.
Use properly skilled staff to develop products, write processes, and conduct maintenance.
Focus on quality and configuration management throughout the System, not just the system.
Learn from the past, don’t repeat it.
Time is money.
The Human Element in Unmaintainable Systems

8. Questions?
The Human Element in Unmaintainable Systems