6/21/2004 1 Spacecraft Manufacture and Test Colonel John E. Keesee 6/21/2004 2 Lesson Objective [To introduce and discuss manufacturing and test processes and philosophies 6/21/2004 3 Uniqueness of Satellite Manufacture [Small production runs [Extreme operational environments [Limited repair/replace options after launch [High product cost and importance [High cost test environment [Highly coupled designs minimize weight and maximize performance but yield high complexity 6/21/2004 4 Overall Manufacturing Process [Prepare engineering data l Drawings, specifications, and processes [Manufacture component [Qualify the component [Integrate and test [Repeat for other components and at higher levels of assembly 6/21/2004 5 Classic Manufacturing Processes [Raw materials ordered from certified vendors [High reliability (S-level) electronic piece parts l Group A, B, and C testing to ensure part quality [Project approved parts and materials lists [Clean rooms for critical assemblies 6/21/2004 6 Clean Rooms Facility/Operation Cleanliness Mechanical Manufacturing Not controlled Electronic assembly Class 10,000 Electromechanical assembly Class 100 Inertial instruments Class 100 Optical Assembly Class 100 Spacecraft Assembly and Test Class 100,000 6/21/2004 7 Classical Quality Assurance [Identify points in process flow where we can make sure the hardware construction complies with engineering data before the next steps prevent inspection [Test surveillance certifies test equipment and processes [Quality assurance records all failures and anomalies 6/21/2004 8 Qualification Test [Establishes that the design has suitable l Performance l Capacity to survive the operating environment [Includes vibration, shock, launch acoustics and the temperature extremes of space [Unique functional performance tests in each environment 6/21/2004 9 Designing for Manufacturability [Traditional approach to quality (test/retest) is high cost and takes a long time [New approaches use concurrent engineering and lean manufacturing processes to reduce cost and ensure quality 6/21/2004 10 Lean Manufacturing [Establishes and implements quality goals in the design phase [Focuses on the processes [Minimizes wasted time and effort [Involves manufacturing personnel in the design effort [Minimizes work in progress 6/21/2004 11 Test Philosophies [Design verification establishes the performance of the design in functional test, vibration, shock, and space environments l Moving toward limiting verification to initial system [Process verification establishes the performance of the production system l The focus of lean manufacturing 6/21/2004 12 Part Selection Criteria [Cost - S-level parts are not always required [Interchangeability - Ease of remove/replace [Simplicity - Cheaper, fewer installation issues, higher reliability [Availability - Just In Time delivery minimizes inventory l Reduces part cost, handling, waste due to obsolescence and redesign 6/21/2004 13 Concurrent Engineering [Involves manufacturing and test personnel in the design team [Refines the design while changes are relatively inexpensive [Permits quality, manufacturability, and profit to be designed into the system 6/21/2004 14 Test Reduction [High quality processes that are well characterized, controlled and repeatable permit testing to be reduced [Continuous process improvement until the process, not inspection, guarantees quality l Reduces inspection points [Reduced testing reduces opportunities to inject variability 6/21/2004 15 Process Characterization Process [Process definition [Process capability l Establish current level of process performance [Process optimization l Focus on key metrics l Determine which variables influence process output [Process control 6/21/2004 16 Learning Cycles [Simulation packages model and predict performance [Prototypes allow physical evaluation [Pathfinding models handling, manufacturing and logistics activities 6/21/2004 17 Conclusion [Modern spacecraft manufacturing seeks to design-in quality and manufacturability to reduce cost and time to market.