What is Quality? FOD & ESD Presented by Janey Diogo 1 Agenda • Quality – Aerospace and Aviation • Foreign Object Debris (FOD) • Electrostatic Discharge (ESD) 2 What is Quality? • Quality is conformance to requirements. – For the product and the customer's requirements. – The system of quality is prevention. – The performance standard is zero defects (relative to requirements). – The measurement of quality is the price of nonconconformance. • Philip Crosby, a well known guru of Quality Management said “It is less expensive to do it right the first time than to pay for rework & repairs. • 3 Quality Assurance • A systematic process of checking to see whether a product or service being developed is meeting specified requirements. – Quality Assurance is a monitoring process. 4 Quality Control • A measure of excellence or a state of being free from defects, deficiencies and significant variations. – Quality Control is an evaluation process. 5 Quality History 1901 - Sir John Wolfe-Barry (the man who designed London's Tower Bridge) instigated the Council of the Institution of Civil Engineers to form a committee to consider standardizing iron and steel sections 1937 - Joseph Juran Introduced the Pareto principle (80/20 rule) 1937 - Hindenburg explosion 36 lives lost (ESD) 1946 - International Organization for Standardization founded in Geneva, Switzerland and the American Society for Quality Control (ASQC) was formed 1960 - First Quality Control Circles formed in Japan 1967 - Apollo 1 fire (ESD) 3 lives lost 1967 1970 - Apollo 13 Oxygen tank explosion (ESD) – No lives lost 6 Quality History 1977 - International Quality Control Circles formed 1979 - British Standard BS 5750 issued (replaced by ISO 9001 in 1987) 1980 - Aviation System Standards (AVN) focused on safety operations Managed by the FAA Safety and Quality Assurance Office 1986 - Six Sigma formulated by Bill Smith (Motorola) 1986 - Kaizen Institute established 1987 - Malcom Baldrige National Quality Award established 1988 - European Foundation for Quality management established by 14 European countries. 2000 - Air France Flight 4590 Concorde accident (FOD on runway) 113 lives lost 2003 - Shuttle Columbia disaster (FOD) – 7 lives lost 2009 - US Airways Flight 1549 (FOD - Bird strike) – No lives lost 7 Foreign Object Debris (FOD) • NASA Definition: • Typical FOD items are A substance or article alien to – aircraft parts, a vehicle or system which – tire fragments, would potentially cause – mechanics’ tools, damage. – nails, • FAA Definition: – luggage parts, FOD is any foreign object that – broken pavement and stones. does not belong on the runway, taxiway, or ramp area. • FOD can cause damage to aircraft, and in rare instances, cause an accident. 8 Examples of FOD • Aircraft parts, rocks, broken pavement, ramp equipment. • Parts from ground vehicles • Garbage, maintenance tools, etc. mistakenly or purposely deposited on tarmac and/or runway surfaces. • Hail: can break windshields and damage or stop engines. • Ice on the wings, propellers, or engine intakes • Bird collisions with engines or other sensitive parts of the aircraft. • Dust or ash clogging the air intakes (as in sandstorms in desert operating conditions or ash clouds in volcanic eruptions). For helicopters, this is also a major problem during a brownout. • Tools, bolts, metal shavings, lockwire, etc. mistakenly left behind inside aircraft during the manufacturing process or maintenance. FOD Prevention • FOD Prevention Program – Training – Inspection – Maintenance – Coordination • FOD PREVENTION–It’s Up to You! 10 FOD • FOD costs industry ~ $12 Billion per year – Reference – Aviation Knowledge • FOD is preventable through proper controls and programs – Awareness + Prevention = Compliance 11 FOD Control 12 FOD Areas 13 FOD On Orbit & Runways A drifting thermal blanket 1998 during STS -88 Air France Flight 4590 25 July 2000 Prevention Cost of Quality 14 Orbiter Columbia Accident Feb 1, 2003 • ET Foam debris (FOD) impacted orbiter left wing damaging the RCC panels during accent • Super heated air penetrates the wing on reentry resulting in structural failure and orbiter breakup • Loss of seven astronauts Impacted program schedules • Costs are incalculable. Prevention Cost of Quality 15 FOD in Flight & in Cleanrooms Prevention Cost of Quality US Airways flight 1549 Bird Strike 16 FOD Key Points • FOD can threaten mission success • FOD can occur anywhere • FOD can be prevented through: – Training – Inspection – Maintenance – Coordination For More Information on FOD • FAA Fact Sheet – FOD https://www.faa.gov/news/fact_sheets/news_story.cfm?newsId=15394 • NASA Document - Foreign Object Debris (FOD) GLPR-5335.1 Presentation aviationknowledge.wikidot.com/aviation:foreign-object-damage • FOD courses available on line through https://asq.org/ Electrostatic Discharge (ESD) • A transfer of electrostatic charge between bodies at different electrostatic potentials caused by direct contact or induced by an electrostatic field. 19 ESD Prevention Program • Elimination of ESD charges in the workplace – This is easier said than done because it’s difficult to ground everything. • Identification of ESD items • Protective materials and equipment • Protected areas and work stations • Monitoring of the work place • Handling ESD items • Packaging, marking and shipping of ESD items 20 ESD Awareness Symbols ESD ESD ESD Susceptibility Symbol Protective Symbol Common Point Ground 21 Hindenburg disaster May 6, 1937 The German passenger airship LZ 129 Hindenburg caught fire and was destroyed during its attempt to dock with its mooring mast at Naval Air Station, Lakehurst Maxfield Field, Jackson Township, NJ Loss of life - 36 Identification of Sources @ Design Elimination Protection Monitoring Device 22 Apollo 1 Accident Virgil Grissom Edward White II Roger Chaffee Apollo 1 fire (ESD) Identification 3 lives lost Jan 27, 1967 Elimination Protection Manned Apollo flights Monitoring were suspended for 20 months 23 Apollo XIII Failure Gordon Copper Donn Eisele Ed Mitchell #2 Oxygen tank Short circuit in service Module's number 2 oxygen tank (ESD) April 13, 1970 Identification Elimination No loss of life Protection Monitoring ESD Packaging, Handling and Prevention ESD Prevention Identification Elimination Anti-Static Bag Protection Static Wrist Strap Monitoring Handling & Packaging ESD Packaging Handling & ESD Packaging Anti-Static Tape Aircraft Static Discharger 25 ESD Key Points • ESD can threaten mission success • ESD can occur anywhere • ESD can be prevented through: – Elimination – Identification – Protective materials and equipment • Protected areas and work stations – Monitoring of the work place – Handling, packaging, marking and shipping For More Information on ESD • ESD Definition NASA-HANDBOOK 8739.21 National Aeronautics and Space Administration Washington, DC 20546 Approved: 2010-06-18 • ESD Awareness Symbols defined in ANSI/ESD S8.1: Summary • My career spanned 35 years in aviation and aerospace across this country and around the globe. Work Ethic/ Requirements Drawings • I was a Licensed FAA Air Traffic Honesty/Trust Controller in the United States Army and worked on the Space Shuttle Program, The International Space Station Program, and the Ground Communications Compliance Standards Missile Defense Program. • Every job required Quality, whether Air Traffic Control, Quality Inspection, Quality Engineer, Systems Engineer, Software Integration Engineer or Handbooks Standards Customer Satisfaction Task Leader. • The following are some of the elements of QUALITY that I experienced: 28 Conclusion • QUALITY is living up to the trust your team has in you. Trust that you will do your job to the best of your ability What is Quality to you? and do the right thing even when no one is looking. What will be your story in 30 or • All of these things are why I 40 years? say that Quality is a Way of Life. • Everyone is responsible regardless of your job title. 29 Backups 30 31 Quality Quotes • Quality is Job One • Never doubt that a small group of Thoughtful, committed citizen can change the world indeed it always has – Margaret Mead, Anthropologist • The quality of an organization can never exceed the quality of the minds that make it up – Dwight Eisenhower • The quality of an organization can never exceed the quality of the minds that make it up. – George Washington • “Quality means doing it right when no one is looking.” – Henry Ford • “Men acquire a particular quality by constantly acting a particular way... you become just by performing just actions, temperate by performing temperate actions, brave by performing brave actions.” – Aristotle 32.