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NASA NTRSDate not supplied

Managing Maintenance Error: Six Lessons From Aviation Maintenance

There are clear parallels between the ground processing of spacecraft and the maintenance of airline aircraft. In both cases, reliable human performance is critical to safe outcomes. Examples of human factors in airline maintenance and spacecraft ground processing illustrate the similarities between these two domains. The worldwide aviation industry began to pay close attention to human factors in maintenance after several maintenance-related disasters in the 1970s and 80s. Rather than simply applying solutions that had been developed for flight crew and air traffic controllers, the aviation industry developed human factors interventions specifically tailored for maintenance personnel. These interventions have led to safety improvements, greater reliability, and significant cost savings. Six human factors approaches from airline maintenance that can be usefully applied to enhance the quality and safety of ground processing are outlined. These are 1) Design for assembly, test, and maintenance, 2) Non technical skills training, 3) Improved design of documentation, 4) Reduction of iatrogenic quality lapses, 5) Barrier and control analysis, and 6) Continuous improvement based on learning from quality lapses.

maintenance human factors↗

NASA NTRS1990

Attitude Determination and Control System (ADCS) and Maintenance and Diagnostic System (MDS): A maintenance and diagnostic system for Space Station Freedom

The Maintenance and Diagnostic System (MDS) that is being developed at Honeywell to enhance the Fault Detection Isolation and Recovery system (FDIR) for the Attitude Determination and Control System on Space Station Freedom is described. The MDS demonstrates ways that AI-based techniques can be used to improve the maintainability and safety of the Station by helping to resolve fault anomalies that cannot be fully determined by built-in-test, by providing predictive maintenance capabilities, and by providing expert maintenance assistance. The MDS will address the problems associated with reasoning about dynamic, continuous information versus only about static data, the concerns of porting software based on AI techniques to embedded targets, and the difficulties associated with real-time response. An initial prototype was built of the MDS. The prototype executes on Sun and IBM PS/2 hardware and is implemented in the Common Lisp; further work will evaluate its functionality and develop mechanisms to port the code to Ada.

Toms, David↗

NASA NTRS1987

IMIS: Integrated Maintenance Information System. A maintenance information delivery concept

The Integrated Maintenance Information System (IMIS) will optimize the use of available manpower, enhance technical performance, improve training, and reduce the support equipment and documentation needed for deployment. It will serve as the technician's single, integrated source of all the technical information required to perform modern aircraft maintenance.

Vonholle, Joseph C.↗

NASA NTRS2002

Primary Mirror Figure Maintenance of the Hobby-Eberly Telescope using the Segment Alignment Maintenance System

The Segment Alignment Maintenance System (SAMs) was installed on McDonald Observatory's Hobby-Eberly Telescope (HET) in August 2001. The SAMs became fully operational in October 2001. The SAMs uses a system of 480 inductive edge sensors to correct misalignments of the HET's 91 primary mirror segments when the segments are perturbed from their aligned reference positions. A special observer estimated and corrects for the global radius of curvature (GroC) mode, a mode unobservable by the edge sensors. The SAMs edge sensor system and (GroC) estimator are able to maintain HET's primary figure for much longer durations than previously had been observed. Telescope image quality has improved, and the amount of overhead time required from primary mirror alignment has been reduced. This paper gives a functional description of the SAMs control system and presents performance verification data. This paper also describes how the SAMs has improved the operational efficiency of the HET.

Rakoczy, John↗

NASA NTRS2007

A NASA Perspective on Maintenance Activities and Maintenance Crews

Proactive consideration of ground crew factors enhances the designs of space vehicles and vehicle safety by: (1) Reducing the risk of undetected ground crew errors and collateral damage that compromise vehicle reliability and flight safety (2) Ensuring compatibility of specific vehicle to ground system interfaces (3) Optimizing ground systems. During ground processing and launch operations, public safety, flight crew safety, ground crew safety, and the safety of high-value spacecraft are inter-related. For extended Exploration missions, surface crews perform functions that merge traditional flight and ground operations.

Barth Tim↗

NASA NTRS1991

Facilities maintenance handbook

This handbook is a guide for facilities maintenance managers. Its objective is to set minimum facilities maintenance standards. It also provides recommendations on how to meet the standards to ensure that NASA maintains its facilities in a manner that protects and preserves its investment in the facilities in a cost-effective manner while safely and efficiently performing its mission. This handbook implements NMI 8831.1, which states NASA facilities maintenance policy and assigns organizational responsibilities for the management of facilities maintenance activities on all properties under NASA jurisdiction. It is a reference for facilities maintenance managers, not a step-by-step procedural manual. Because of the differences in NASA Field Installation organizations, this handbook does not assume or recommend a typical facilities maintenance organization. Instead, it uses a systems approach to describe the functions that should be included in any facilities maintenance management system, regardless of its organizational structure. For documents referenced in the handbook, the most recent version of the documents is applicable. This handbook is divided into three parts: Part 1 specifies common definitions and facilities maintenance requirements and amplifies the policy requirements contained in NMI 8831. 1; Part 2 provides guidance on how to meet the requirements of Part 1, containing recommendations only; Part 3 contains general facilities maintenance information. One objective of this handbook is to fix commonality of facilities maintenance definitions among the Centers. This will permit the application of uniform measures of facilities conditions, of the relationship between current replacement value and maintenance resources required, and of the backlog of deferred facilities maintenance. The utilization of facilities maintenance system functions will allow the Centers to quantitatively define maintenance objectives in common terms, prepare work plans, and develop management information in order to statistically identify and analyze variances from those plans. It will also add credibility to the NASA facilities maintenance budgeting process. The key to a successful maintenance program is the understanding and support of the senior Center managers.

Source record↗

NASA NTRSDate not supplied

Assessment of Crew Time for Maintenance and Repair Activities for Lunar Surface Missions

NASA is currently evaluating different methods to predict how much time crewmembers will spend conducting repair and maintenance activities on future space missions. As mission scope and spacecraft architectures change, understanding how crew repair and maintenance timelines are impacted by mission operations and technology changes is vital for future mission planning. Past work has been done using historical International Space Station (ISS) data to accurately predict crew habitation and operation timelines, resulting in the development of NASA’s Exploration Crew Time Model (ECTM). However, understanding crew maintenance and repair requirements has posed a unique challenge due to the complexity of available datasets, the probabilistic nature of sub-system failures, and the impacts of reliability growth on failure rates. This paper presents a methodology to collect and condition empirical repair and maintenance time data from available datasets, to extrapolate from that data to estimate projected maintenance and repair times for a lunar Surface Habitat (SH), and to assess how uncertainty in repair time could impact utilization time on the lunar surface. NASA ISS maintenance and crew time data are logged into two central databases: the Maintenance Data Collection (MDC) and the Operations Planning Timeline Integration System (OPTimIS). Separately, each of these two datasets capture only portions of the complete set of data required to generate an accurate assessment of crew time spent on maintenance activities at a sub-system level. To create a more useful crew time estimate for maintenance timelines, the authors developed a methodology to capture relevant data from each set and combine and utilize that data by linking crew time requirements to specific components. The authors compare the failure logs in the MDC to crew activity logs pulled from OPTimIS and then process the data to estimate required repair time for each failure and repair event. The entire maintenance activity dataset is then categorized based on the class of failed component to ensure a significant sample size for each class and accurate crew time estimates for any components lacking relevant data. This resultant component repair time data can be used in the future to generate Mean Time to Repair (MTTR) estimates and confidence intervals for each class of component based on a probabilistic distribution of documented maintenance events. These improved MTTR values can then be applied to candidate element sub-system architectures, along with component Mean Time Between Failure (MTBF) data to generate distributions for potential required system crew repair time estimates for a given mission. The authors applied these modeling methods to a case study of a crewed mission to the planned SH and produced expected corrective maintenance crew time distributions. The results produced an expected corrective maintenance crew time at over 24 hours per mission, and a maintenance crew time distribution that reflects the importance of planning for sufficient maintenance requirements each mission. Repair time distributions can then be used to develop more accurate crew schedules and to assess potential available utilization time.

Crew Time↗

NASA NTRSDate not supplied

Assessment of Crew Time for Maintenance and Repairs Activities for Lunar Surface Missions

NASA is currently evaluating different methods to predict how much time crewmembers will spend conducting repair and maintenance activities on future space missions. As mission scope and spacecraft architectures change, it will be necessary to understand how crew repair and maintenance timelines are impacted by mission operations and technology changes. Past work has been done using historical ISS data to accurately predict crew habitation and operation timelines, resulting in the development of NASA’s Exploration Crew Time Model (ECTM). However, understanding crew maintenance and repair requirements has posed a unique challenge due to the complexity of available datasets, the probabilistic nature of sub-system failures, and the impacts of reliability growth on failure rates. This paper presents a methodology to collect and condition empirical repair and maintenance time data from available data sets, to extrapolate from that data to estimate projected maintenance and repair times for a lunar Surface Habitat, and to assess how uncertainty in repair time could impact utilization time on the lunar surface. NASA International Space Station (ISS) maintenance and crew time data are logged into two central databases, the Maintenance Data Collection (MDC) and the Operations Planning Timeline Integration System (OPTimIS) respectively. Separately, each of these two datasets capture only portions of the complete set of data required to generate an accurate assessment of crew time spent on maintenance activities at a sub-system level. MDC provides a detailed catalog of failure events and an overview of the failure’s required maintenance and OPTimIS provides a description of crew activities and crew time durations dedicated to maintenance. To create a more useful crew time estimate for maintenance timelines, the authors developed a methodology to capture relevant data from each set and combine and utilize that data by linking crew time requirements to specific components. The authors compare the failure logs in the MDC to crew activity logs pulled from OPTimIS and then process the data to estimate required repair times for each failure event. Data is also classified by the outcome of each repair event, whether the failed component was replaced or whether it was repaired in place. The entire maintenance activity dataset is then categorized based on the class of failed component to allow for a statistically significant sample size for each class and to provide accurate crew time estimates for any components lacking relevant data. This resultant component repair time data can be used in the future to generate Mean Time To Repair (MTTR) estimates and confidence intervals for each class of component based on a probabilistic distribution of documented maintenance events. These improved MTTR values can then be applied to candidate element sub-system architectures, along with component Mean Time Between Failure (MTBF) data to generate distributions for potential required system crew repair time estimates for a given mission. Repair time distributions can then be used to develop more accurate crew schedules and to assess potential available utilization time.

Crew Time↗

NASA NTRS1972

Space shuttle maintenance program planning document

A means for developing a space shuttle maintenance program which will be acceptable to the development centers, the operators (KSC and AF), and the manufacturer is presented. The general organization and decision processes for determining the essential scheduled maintenance requirements for the space shuttle orbiter are outlined. The development of initial scheduled maintenance programs is discussed. The remaining maintenance, that is non-scheduled or non-routine maintenance, is directed by the findings of the scheduled maintenance program and the normal operation of the shuttle. The remaining maintenance consists of maintenance actions to correct discrepancies noted during scheduled maintenance tasks, nonscheduled maintenance, normal operation, or condition monitoring.

Brown, D. V.↗

NASA NTRS2023

An Analysis of Barriers Preventing the Widespread Adoption of Predictive and Prescriptive Maintenance in Aviation

The aviation industry has long recognized the potential benefits of predictive maintenance, a maintenance strategy that leverages sensor and operational data to predict the future degradation of components. Prescriptive maintenance takes this a step further and considers the entire aviation ecosystem to schedule maintenance actions optimally. With the ability to reduce maintenance costs by up to 30%, as reported by the Department of Energy, these maintenance strategies have been identified to be an important investment to reduce a airline costs. However, despite great interest and technological advances in areas such as diagnostics, prognostics, sensing, computation, and machine learning, the adoption of predictive and prescriptive maintenance has not been widely applied in aviation. To shed light on this issue, we conducted an analysis of the barriers preventing or limiting the adoption of predictive and prescriptive maintenance in aviation. Through discussions with subject matter experts across industry, academia, standards bodies, and government, we identified five key challenges: complexity of prediction; validation, safety assurance, and regulatory challenges; cost of adoption; difficulty in quantifying impact and informing decisions; and data availability, quality, and ownership challenges. This study provides a detailed overview of these barriers and areas where stakeholders could invest to overcome them, aiming to support the scaled adoption of predictive and prescriptive maintenance in aviation.

Christopher Teubert↗

NASA NTRS1992

Toward full life cycle control: Adding maintenance measurement to the SEL

Organization-wide measurement of software products and processes is needed to establish full life cycle control over software products. The Software Engineering Laboratory (SEL)--a joint venture between NASA GSFC, the University of Maryland, and Computer Sciences Corporation--started measurement of software development more than 15 years ago. Recently, the measurement of maintenance was added to the scope of the SEL. In this article, the maintenance measurement program is presented as an addition to the already existing and well-established SEL development measurement program and evaluated in terms of its immediate benefits and long-term improvement potential. Immediate benefits of this program for the SEL include an increased understanding of the maintenance domain, the differences and commonalities between development and maintenance, and the cause-effect relationships between development and maintenance. Initial results from a sample maintenance study are presented to substantiate these benefits. The long-term potential of this program includes the use of maintenance baselines to better plan and manage future projects and to improve development and maintenance practices for future projects wherever warranted.

Rombach, H. Dieter↗

NASA NTRS1993

Test, Control and Monitor System maintenance plan

The maintenance requirements for Test, Control, and Monitor System (TCMS) and the method for satisfying these requirements prior to First Need Date (FND) of the last TCMS set are described. The method for satisfying maintenance requirements following FND of the last TCMS set will be addressed by a revision to this plan. This maintenance plan serves as the basic planning document for maintenance of this equipment by the NASA Payloads Directorate (CM) and the Payload Ground Operations Contractor (PGOC) at KSC. The terms TCMS Operations and Maintenance (O&M), Payloads Logistics, TCMS Sustaining Engineering, Payload Communications, and Integrated Network Services refer to the appropriate NASA and PGOC organization. For the duration of their contract, the Core Electronic Contractor (CEC) will provide a Set Support Team (SST). One of the primary purposes of this team is to help NASA and PGOC operate and maintain TCMS. It is assumed that SST is an integral part of TCMS O&M. The purpose of this plan is to describe the maintenance concept for TCMS hardware and system software in order to facilitate activation, transition planning, and continuing operation. When software maintenance is mentioned in this plan, it refers to maintenance of TCMS system software.

Buehler, David P.↗

NASA NTRS1992

Determining maintenance cost ratios

This paper reports on the wide range of costs involved in maintaining equipment and discusses methods that different industries use to measure and report their maintenance cost. Results are presented of the study of maintenance costs in the NASA Deep Space Network (DSN) and of a comparison of DSN maintenance cost with the maintenance costs of a number of other reports. A comparison of the maintenance costs in terms of the maintenance cost ratio (annual maintenance cost/capital replacement cost) shows that DSN has the lowest maintenance cost ratio of the industries and organizations surveyed.

Remer, Donald S.↗

NASA NTRS1996

Understanding and Predicting the Process of Software Maintenance Releases

One of the major concerns of any maintenance organization is to understand and estimate the cost of maintenance releases of software systems. Planning the next release so as to maximize the increase in functionality and the improvement in quality are vital to successful maintenance management. The objective of this paper is to present the results of a case study in which an incremental approach was used to better understand the effort distribution of releases and build a predictive effort model for software maintenance releases. This study was conducted in the Flight Dynamics Division (FDD) of NASA Goddard Space Flight Center(GSFC). This paper presents three main results: 1) a predictive effort model developed for the FDD's software maintenance release process; 2) measurement-based lessons learned about the maintenance process in the FDD; and 3) a set of lessons learned about the establishment of a measurement-based software maintenance improvement program. In addition, this study provides insights and guidelines for obtaining similar results in other maintenance organizations.

Basili, Victor↗

NASA NTRS1973

Phase 111A Crew Interface Specifications Development for Inflight Maintenance and Stowage Functions

This report presents the findings and data products developed during the Phase IIIA Crew Interface Specification Study for Inflight Maintenance and Stowage Functions, performed by General Electric for the NASA, Johnson Space Center with a set of documentation that can be used as definitive guidelines to improve the present process of defining, controlling and managing flight crew interface requirements that are related to inflight maintenance (including assembly and servicing) and stowage functions. During the Phase IIIA contract period, the following data products were developed: 1) Projected NASA Crew Procedures/Flight Data File Development Process. 2) Inflight Maintenance Management Process Description. 3) Preliminary Draft, General Specification, Inflight Maintenance Management Requirements. 4) Inflight Maintenance Operational Process Description. 5) Preliminary Draft, General Specification, Inflight Maintenance Task and Support Requirements Analysis. 6) Suggested IFM Data Processing Reports for Logistics Management The above Inflight Maintenance data products have been developed during the Phase IIIA study after review of Space Shuttle Program Documentation, including the Level II Integrated Logistics Requirements and other DOD and NASA data relative to Payloads Accommodations and Satellite On-Orbit Servicing. These Inflight Maintenance data products were developed to be in consonance with Space Shuttle Program technical and management requirements.

Carl, John G.↗

NASA NTRS2007

A Study to Estimate the Effectiveness of Visual Testing Training for Aviation Maintenance Management

The Air Commerce Act of 1926 set the beginning for standards in aviation maintenance. Even after deregulation in the late l970s, maintenance standards and requirements still have not changed far from their initial criteria. After a potential candidate completes Federal Aviation Administration training prerequisites, they may test for their Airframe and Powerplant (A&P) certificate. Performing maintenance in the aviation industry for a minimum of three years, the technician may then test for their Inspection Authorization (IA). After receiving their Airframe and Powerplant certificate, a technician is said to have a license to perform. At no time within the three years to eligibility for Inspection Authorization are they required to attend higher-level inspection training. What a technician learns in the aviation maintenance industry is handed down from a seasoned technician to the new hire or is developed from lessons learned on the job. Only in Europe has the Joint Aviation Authorities (JAA) required higher-level training for their aviation maintenance technicians in order to control maintenance related accidents (Lu, 2005). Throughout the 1990s both the General Accounting Office (GAO) and the National Transportation Safety Board (NTSB) made public that the FAA is historically understaffed (GAO, 1996). In a safety recommendation the NTSB stated "The Safety Board continues to lack confidence in the FAA's commitment to provide effective quality assurance and safety oversight of the ATC system (NTSB, 1990)." The Federal Aviation Administration (FAA) has been known to be proactive in creating safer skies. With such reports you would suspect the FAA to also be proactive in developing more stringent inspection training for aviation maintenance technicians. The purpose of this study is to estimate the effectiveness of higher-level inspection training, such as Visual Testing (VT) for aviation maintenance technicians, to improve the safety of aircraft and to make recommendations to management with regard to the value of such training.

Law, Lewis Lyle↗

NASA NTRS1992

Crew considerations in the design for Space Station Freedom modules on-orbit maintenance

The paper presents an approach to the maintenance process currently planned for the Space Station Freedom modules. In particular, it describes the planned crew interfaces with maintenance items, and the anticipated implications for the crew in performing the interior and exterior maintenance of modules developed by U.S., ESA, and NASDA. Special consideration is given to the maintenance requirements, allocations, and approach; the maintenance design; the Maintenance Workstation; the robotic mechanisms; and the developemnt of maintenance techniques.

Stokes, Jack W.↗

NASA NTRS1993

Forecasting the impact of virtual environment technology on maintenance training

To assist NASA and the Air Force in determining how and when to invest in virtual environment (VE) technology for maintenance training, we identified possible roles for VE technology in such training, assessed its cost-effectiveness relative to existing technologies, and formulated recommendations for a research agenda that would address instructional and system development issues involved in fielding a VE training system. In the first phase of the study, we surveyed VE developers to forecast capabilities, maturity, and estimated costs for VE component technologies. We then identified maintenance tasks and their training costs through interviews with maintenance technicians, instructors, and training developers. Ten candidate tasks were selected from two classes of maintenance tasks (seven aircraft maintenance and three space maintenance) using five criteria developed to identify types of tasks most likely to benefit from VE training. Three tasks were used as specific cases for cost-benefit analysis. In formulating research recommendations, we considered three aspects of feasibility: technological considerations, cost-effectiveness, and anticipated R&D efforts. In this paper, we describe the major findings in each of these areas and suggest research efforts that we believe will help achieve the goal of a cost-effective VE maintenance training system by the next decade.

Schlager, Mark S.↗