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NASA NTRS2011

Constellation Program: Lessons Learned: Executive Summary - Volume 1

This document (Volume I) provides an executive summary of the lessons learned from the Constellation Program. A companion Volume II provides more detailed analyses for those seeking further insight and information. In this volume, Section 1.0 introduces the approach in preparing and organizing the content to enable rapid assimilation of the lessons. Section 2.0 describes the contextual framework in which the Constellation Program was formulated and functioned that is necessary to understand most of the lessons. Context of a former program may seem irrelevant in the heady days of new program formulation. However, readers should take some time to understand the context. Many of the lessons would be different in a different context, so the reader should reflect on the similarities and differences in his or her current circumstances. Section 3.0 summarizes key findings developed from the significant lessons learned at the program level that appear in Section 4.0. Readers can use the key findings in Section 3.0 to peruse for particular topics, and will find more supporting detail and analyses in Section 4.0 in a topical format. Appendix A contains a white paper describing the Constellation Program formulation that may be of use to readers wanting more context or background information. The reader will no doubt recognize some very similar themes from previous lessons learned, blue-ribbon committee reviews, National Academy reviews, and advisory panel reviews for this and other large-scale human spaceflight programs; including Apollo, Space Shuttle, Shuttle/Mir, and the ISS. This could represent an inability to learn lessons from previous generations; however, it is more likely that similar challenges persist in the Agency structure and approach to program formulation, budget advocacy, and management. Perhaps the greatest value of these Constellation lessons learned can be found in viewing them in context with these previous efforts to guide and advise the Agency and its stakeholders.

Constellation Program↗
NASA NTRS2005

Engineering Lessons Learned and Systems Engineering Applications

Systems Engineering is fundamental to good engineering, which in turn depends on the integration and application of engineering lessons learned. Thus, good Systems Engineering also depends on systems engineering lessons learned from within the aerospace industry being documented and applied. About ten percent of the engineering lessons learned documented in the NASA Lessons Learned Information System are directly related to Systems Engineering. A key issue associated with lessons learned datasets is the communication and incorporation of this information into engineering processes. As part of the NASA Technical Standards Program activities, engineering lessons learned datasets have been identified from a number of sources. These are being searched and screened for those having a relation to Technical Standards. This paper will address some of these Systems Engineering Lessons Learned and how they are being related to Technical Standards within the NASA Technical Standards Program, including linking to the Agency's Interactive Engineering Discipline Training Courses and the life cycle for a flight vehicle development program.

Gill, Paul S.↗
NASA NTRS2006

Human Factors Lessons Learned on the International Space Station

Experience on International Space Station (ISS) provides many important lessons for future space flight. NASA human factors engineers have been systematically collecting lessons learned from crew debriefs, as well as working with ground support teams to continuously improve crew operations. This paper describes the methods for collecting data from debriefs, lessons learned through that process, and an example of a technology development task funded through the Space Human Factors Engineering (SHFE) program element in response to an identified operational need. Each ISS increment crew spends many hours after the flight answering questions from the various subsystem leads. The Flight Crew Integration subsystem lead asks questions specific to human factors and habitability issues. In addition, crew comments on many other subsystems provide insight into interface designs, operability and maintainability. The debrief comments are unique to each crew, and must be categorized to provide operational lessons learned. Personal identifiers are removed and comments aggregated to separate consistent issues from personal preferences. Examples will be given, and the procedure for incorporating the lessons into requirements and guidelines for the next human space vehicle will be described. In flight, very few astronauts are medical doctors. Written medical procedures during flight need to be easy to follow and quick to understand. The problem was analyzed as part of a SHFE task. Organization was analyzed and reorganizations were created and tested. Results will be reported. The ISS is a very important analog for planning future long-term missions. Collection of data from debriefs, studying the lessons learned and focusing on requirements for future missions are examples of the accomplishments through the SHFE program.

Woolford, Barbara↗
NASA NTRS2013

PV Reliability Development Lessons from JPL's Flat Plate Solar Array Project

Key reliability and engineering lessons learned from the 20-year history of the Jet Propulsion Laboratory's Flat-Plate Solar Array Project and thin film module reliability research activities are presented and analyzed. Particular emphasis is placed on lessons applicable to evolving new module technologies and the organizations involved with these technologies. The user-specific demand for reliability is a strong function of the application, its location, and its expected duration. Lessons relative to effective means of specifying reliability are described, and commonly used test requirements are assessed from the standpoint of which are the most troublesome to pass, and which correlate best with field experience. Module design lessons are also summarized, including the significance of the most frequently encountered failure mechanisms and the role of encapsulate and cell reliability in determining module reliability. Lessons pertaining to research, design, and test approaches include the historical role and usefulness of qualification tests and field tests.

photovoltaics↗
NASA NTRS1985

Crystalline-silicon reliability lessons for thin-film modules

Key reliability and engineering lessons learned from the 10-year history of the Jet Propulsion Laboratory's Flat-Plate Solar Array Project are presented and analyzed. Particular emphasis is placed on lessons applicable to the evolving new thin-film cell and module technologies and the organizations involved with these technologies. The user-specific demand for reliability is a strong function of the application, its location, and its expected duration. Lessons relative to effective means of specifying reliability are described, and commonly used test requirements are assessed from the standpoint of which are the most troublesome to pass, and which correlate best with field experience. Module design lessons are also summarized, including the significance of the most frequently encountered failure mechanisms and the role of encapsulant and cell reliability in determining module reliability. Lessons pertaining to research, design, and test approaches include the historical role and usefulness of qualification tests and field tests.

Ross, Ronald G., Jr.↗
NASA NTRS1993

Lift-fan aircraft: Lessons learned-the pilot's perspective

This paper is written from an engineering test pilot's point of view. Its purpose is to present lift-fan 'lessons learned' from the perspective of first-hand experience accumulated during the period 1962 through 1988 while flight testing vertical/short take-off and landing (V/STOL) experimental aircraft and evaluating piloted engineering simulations of promising V/STOL concepts. Specifically, the scope of the discussions to follow is primarily based upon a critical review of the writer's personal accounts of 30 hours of XV-5A/B and 2 hours of X-14A flight testing as well as a limited simulator evaluation of the Grumman Design 755 lift-fan aircraft. Opinions of other test pilots who flew these aircraft and the aircraft simulator are also included and supplement the writer's comments. Furthermore, the lessons learned are presented from the perspective of the writer's flying experience: 10,000 hours in 100 fixed- and rotary-wing aircraft including 330 hours in 5 experimental V/STOL research aircraft. The paper is organized to present to the reader a clear picture of lift-fan lessons learned from three distinct points of view in order to facilitate application of the lesson principles to future designs. Lessons learned are first discussed with respect to case histories of specific flight and simulator investigations. These principles are then organized and restated with respect to four selected design criteria categories in Appendix I. Lastly, Appendix Il is a discussion of the design of a hypothetical supersonic short take-off vertical landing (STOVL) fighter/attack aircraft.

Gerdes, Ronald M.↗
NASA NTRS1999

COSS Lesson Creation Process

COSS (Crew On-Orbit System Support) is changing. Designed as computer based in-flight refresher training, it is getting good reviews and the demands on the product can be expected to increase. Last year, the lessons were written using Authorware, which had a number of limitations. The most important one was that the navigation and the layout functions were both in one package that was not easy to learn. The lesson creator had to be good at both programming and design. There were also a number of other problems, as detailed in my report last year. This year the COSS unit made the switch to embrace modularity. The navigation function is handled by a player that was custom-written using Delphi. The layout pages are now standard HTML files that can be created using any number of products. This new system gives new flexibility and unties the process from one product (and one company). The player can be re-written by a programmer without affecting the lesson pages. It is also now possible for anybody with a word-processor to make part of the HTML lesson pages and to use many of the new commercially available tools that are being designed for web pages. This summer I created a computer-based training (CBT) lesson on the IBM ThinkPad 760 ED and 760XD laptop computers that should fly on the International Space Station. I also examined the COSS system, the new player and the other new software products.

Harper, R. Stephen↗
NASA NTRS2002

Lessons Learned and Technical Standards: A Logical Marriage for Future Space Systems Design

A comprehensive database of engineering lessons learned that corresponds with relevant technical standards will be a valuable asset to those engaged in studies on future space vehicle developments, especially for structures, materials, propulsion, control, operations and associated elements. In addition, this will enable the capturing of technology developments applicable to the design, development, and operation of future space vehicles as planned in the Space Launch Initiative. Using the time-honored tradition of passing on lessons learned while utilizing the newest information technology, NASA has launched an intensive effort to link lessons learned acquired through various Internet databases with applicable technical standards. This paper will discuss the importance of lessons learned, the difficulty in finding relevant lessons learned while engaged in a space vehicle development, and the new NASA effort to relate them to technical standards that can help alleviate this difficulty.

Gill, Paul S.↗
NASA NTRS2010

Launch Vehicle Propulsion Life Cycle Cost Lessons Learned

This paper will review lessons learned for space transportation systems from the viewpoint of the NASA, Industry and academia Space Propulsion Synergy Team (SPST). The paper provides the basic idea and history of "lessons learned". Recommendations that are extremely relevant to NASA's future investments in research, program development and operations are"'provided. Lastly, a novel and useful approach to documenting lessons learned is recommended, so as to most effectively guide future NASA investments. Applying lessons learned can significantly improve access to space for cargo or people by focusing limited funds on the right areas and needs for improvement. Many NASA human space flight initiatives have faltered, been re-directed or been outright canceled since the birth of the Space Shuttle program. The reasons given at the time have been seemingly unique. It will be shown that there are common threads as lessons learned in many a past initiative.

Zapata, Edgar↗
NASA NTRS2017

Lessons Learned from Applying Design Thinking in a NASA Rapid Design Study in Aeronautics

In late 2015, NASA's Aeronautics Research Mission Directorate (ARMD) funded an experiment in rapid design and rapid teaming to explore new approaches to solving challenging design problems in aeronautics in an effort to cultivate and foster innovation. This report summarizes several lessons learned from the rapid design portion of the study. This effort entailed learning and applying design thinking, a human-centered design approach, to complete the conceptual design for an open-ended design challenge within six months. The design challenge focused on creating a capability to advance experimental testing of autonomous aeronautics systems, an area of great interest to NASA, the US government as a whole, and an entire ecosystem of users and developers around the globe. A team of nine civil servant researchers from three of NASA's aeronautics field centers with backgrounds in several disciplines was assembled and rapidly trained in design thinking under the guidance of the innovation and design firm IDEO. The design thinking process, while used extensively outside the aerospace industry, is less common and even counter to many practices within the aerospace industry. In this report, several contrasts between common aerospace research and development practices and design thinking are discussed, drawing upon the lessons learned from the NASA rapid design study. The lessons discussed included working towards a design solution without a set of detailed design requirements, which may not be practical or even feasible for management to ascertain for complex, challenging problems. This approach allowed for the possibility of redesigning the original problem statement to better meet the needs of the users. Another lesson learned was to approach problems holistically from the perspective of the needs of individuals that may be affected by advances in topic area instead of purely from a technological feasibility viewpoint. The interdisciplinary nature of the design team also provided valuable experience by allowing team members from different technological backgrounds to work side-by-side instead of dividing into smaller teams, as is frequently done in traditional multidisciplinary design. The team also learned how to work with qualitative data obtained primarily through the 70-plus interviews that were conducted over the course of this project, which was a sharp contrast to using quantitative data with regards to identifying, capturing, analyzing, storing, and recalling the data. When identifying potential interviewees who may have useful contributions to the design subject area, the team found great value in talking to non-traditional users and potential beneficiaries of autonomous aeronautics systems whose impact on the aeronautics autonomy ecosystem is growing swiftly. Finally, the team benefitted from using "sacrificial prototyping," which is a method of rapidly prototyping draft concepts and ideas with the intent of enabling potential users to provide significant feedback early in the design process. This contrasts the more common approach of using expensive prototypes that focus on demonstrating technical feasibility. The unique design approach and lessons learned by the team throughout this process culminated in a final design concept that was quite different than what the team originally assumed would be the design concept initially. A summary of the more usercentered final design concept is also provided.

McGowan, Anna-Maria↗
NASA NTRS2011

Lesson Learning at JPL

A lessons learned system is a hallmark of a mature engineering organization A formal lessons learned process can help assure that valuable lessons get written and published, that they are well-written, and that the essential information is "infused" into institutional practice. Requires high-level institutional commitment, and everyone's participation in gathering, disseminating, and using the lessons

project documentation↗
NASA NTRS2018

An Overview of Lessons Learned from Sonic-boom Flight Research Projects Conducted by NASA Armstrong Flight Research Center

Over the course of four years, a team of aerospace engineers at the National Aeronautics and Space Administration Armstrong Flight Research Center completed four projects, each with the objective to research sonic-boom signatures from a ground-and building-level perspective. The relatively compressed timeline of these projects resulted in many lessons learned. With each successive project, these lessons have been more relied upon and referenced. This paper provides a high-level overview of the teams relevant lessons learned and the importance of these lessons for future projects.

lessons learned↗
NASA NTRS2024

Transitioning Sixty Years of NASA Spacesuit Knowledge Capture Lessons Learned to Searchable Knowledge Transfer Databases

Sixty years of spacesuit knowledge capture and lessons learned by spacesuit subject matter experts are documented on videos and presentations and archived with the NASA Engineering and Safety Center (NESC) Academy. The NESC Academy is a web-based platform that hosts online courses by technical experts. A process is underway to transition these decades of lessons learned from the U.S. Spacesuit Knowledge Capture Program Library into more quicky searchable databases and to proactively provide this information to those working on spacesuit projects. Hundreds of lessons learned from Project Mercury, Gemini, Apollo, Apollo- Soyuz Test Project, Skylab, Space Shuttle, International Space Station, and Artemis have been captured in a format that can be quickly searched, enabling users to find information directly applicable to their needs. Transitioning this information to a NASA wiki page will further enhance search and retrieval of data immediately useful to users. This paper provides information about how the lessons learned were determined and how to access them.

spacesuit↗
NASA NTRSDate not supplied

Transitioning Sixty Years of NASA Spacesuit Knowledge Capture Lessons Learned to Searchable Knowledge Transfer Databases

Sixty years of spacesuit knowledge capture and lessons learned by spacesuit subject matter experts are documented on videos and presentations and archived with the NASA Engineering and Safety Center (NESC) Academy. The NESC Academy is a web-based platform that hosts online courses by technical experts. A process is underway to transition these decades of lessons learned from the U.S. Spacesuit Knowledge Capture Program Library into more quicky searchable databases and to proactively provide this information to those working on spacesuit projects. Hundreds of lessons learned from Project Mercury, Gemini, Apollo, Apollo- Soyuz Test Project, Skylab, Space Shuttle, International Space Station, and Artemis have been captured in a format that can be quickly searched, enabling users to find information directly applicable to their needs. Transitioning this information to a NASA wiki page will further enhance search and retrieval of data immediately useful to users. This paper provides information about how the lessons learned were determined and how to access them.

spacesuit↗
NASA NTRS2002

NASA Materials Related Lessons Learned

Lessons Learned have been the basis for our accomplishments throughout the ages. They have been passed down from father to son, mother to daughter, teacher to pupil, and older to younger worker. Lessons Learned have also been the basis for the nation's accomplishments for more than 200 years. Both government and industry have long recognized the need to systematically document and utilize the knowledge gained from past experiences in order to avoid the repetition of failures and mishaps. Through the knowledge captured and recorded in Lessons Learned from more than 80 years of flight in the Earth's atmosphere, NASA's materials researchers are constantly working to develop stronger, lighter, and more durable materials that can withstand the challenges of space. The Agency's talented materials engineers and scientists continue to build on that rich tradition by using the knowledge and wisdom gained from past experiences to create futurist materials and technologies that will be used in the next generation of advanced spacecraft and satellites that may one day enable mankind to land men on another planet or explore our nearest star. These same materials may also have application here on Earth to make commercial aircraft more economical to build and fly. With the explosion in technical accomplishments over the last decade, the ability to capture knowledge and have the capability to rapidly communicate this knowledge at lightning speed throughout an organization like NASA has become critical. Use of Lessons Learned is a principal component of an organizational culture committed to continuous improvement.

Garcia, Danny↗
NASA NTRS2004

Test Planning Approach and Lessons

As NASA began technology risk reduction activities and planning for the next generation launch vehicle under the Space Launch Initiative (SLI), now the Next Generation Launch Technology (NGLT) Program, a review of past large liquid rocket engine development programs was performed. The intent of the review was to identify any significant lessons from the development testing programs that could be applied to current and future engine development programs. Because the primary prototype engine in design at the time of this study was the Boeing-Rocketdyne RS-84, the study was slightly biased towards LOX/RP-1 liquid propellant engines. However, the significant lessons identified are universal. It is anticipated that these lessons will serve as a reference for test planning in the Engine Systems Group at Marshall Space Flight Center (MSFC). Towards the end of F-1 and J-2 engine development testing, NASA/MSFC asked Rocketdyne to review those test programs. The result was a document titled, Study to Accelerate Development by Test of a Rocket Engine (R-8099). The "intent (of this study) is to apply this thinking and learning to more efficiently develop rocket engines to high reliability with improved cost effectivenes" Additionally, several other engine programs were reviewed - such as SSME, NSTS, STME, MC-1, and RS-83- to support or refute the R-8099. R-8099 revealed two primary lessons for test planning, which were supported by the other engine development programs. First, engine development programs can benefit from arranging the test program for engine system testing as early as feasible. The best test for determining environments is at the system level, the closest to the operational flight environment. Secondly, the component testing, which tends to be elaborate, should instead be geared towards reducing risk to enable system test. Technical risk can be reduced at the component level, but the design can only be truly verified and validated after engine system testing.

Parkinson, Douglas A.↗
NASA NTRS2003

NASA Materials Related Lessons Learned

Lessons Learned have been the basis for our accomplishments throughout the ages. They have been passed down from father to son, mother to daughter, teacher to pupil, and older to younger worker. Lessons Learned have also been the basis for the nation s accomplishments for more than 200 years. Both government and industry have long recognized the need to systematically document and utilize the knowledge gained from past experiences in order to avoid the repetition of failures and mishaps. Through the knowledge captured and recorded in Lessons Learned from more than 80 years of flight in the Earth s atmosphere, NASA s materials researchers are constantly working to develop stronger, lighter, and more durable materials that can withstand the challenges of space. The Agency s talented materials engineers and scientists continue to build on that rich tradition by using the knowledge and wisdom gained from past experiences to create futuristic materials and technologies that will be used in the next generation of advanced spacecraft and satellites that may one day enable mankind to land men on another planet or explore our nearest star. These same materials may also have application here on Earth to make commercial aircraft more economical to build and fly. With the explosion in technical accomplishments over the last decade, the ability to capture knowledge and have the capability to rapidly communicate this knowledge at lightning speed throughout an organization like NASA has become critical. Use of Lessons Learned is a principal component of an organizational culture committed to continuous improvement.

Garcia, Danny↗
NASA NTRS2005

Atmospheric/Space Environment Support Lessons Learned Regarding Aerospace Vehicle Design and Operations

In modern government and aerospace industry institutions the necessity of controlling current year costs often leads to high mobility in the technical workforce, "one-deep" technical capabilities, and minimal mentoring for young engineers. Thus, formal recording, use, and teaching of lessons learned are especially important in the maintenance and improvement of current knowledge and development of new technologies, regardless of the discipline area. Within the NASA Technical Standards Program Website http://standards.nasa.gov there is a menu item entitled "Lessons Learned/Best Practices". It contains links to a large number of engineering and technical disciplines related data sets that contain a wealth of lessons learned information based on past experiences. This paper has provided a small sample of lessons learned relative to the atmospheric and space environment. There are many more whose subsequent applications have improved our knowledge of the atmosphere and space environment, and the application of this knowledge to the engineering and operations for a variety of aerospace programs.

Vaughan, William W.↗