What is Quality?

FOD & ESD

Presented by Janey Diogo

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Agenda

• Quality – Aerospace and Aviation

• Foreign Object Debris (FOD)

• Electrostatic Discharge (ESD)

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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.

•

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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.

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Quality Control

• A measure of excellence or a state of being free

from defects, deficiencies and significant

variations.

– Quality Control is an evaluation process.

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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

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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

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• NASA Definition: A substance or article alien to a vehicle or system which would potentially cause damage.

• FAA Definition: FOD is any foreign object that does not belong on the runway, taxiway, or ramp area.

• FOD can cause damage to aircraft, and in rare instances, cause an accident.

• Typical FOD items are– aircraft parts,

– tire fragments,

– mechanics’ tools,

– nails,

– luggage parts,

– broken pavement and stones.

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Foreign Object Debris (FOD)

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!

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FOD

• FOD costs industry ~ $12 Billion per year

– Reference – Aviation Knowledge

• FOD is preventable through proper controls and

programs

– Awareness + Prevention = Compliance

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FOD Control

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FOD Areas

FOD On Orbit & Runways

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A drifting thermal blanket

1998 during STS -88 Air France Flight 4590 25 July 2000

Prevention

Cost of Quality

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• 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

Orbiter Columbia Accident Feb 1, 2003

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US Airways flight 1549

Bird Strike

Prevention

Cost of

Quality

FOD in Flight & in Cleanrooms

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 – FODhttps://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 throughhttps://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.

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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

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ESD Awareness Symbols

ESD

Susceptibility Symbol

ESD

Protective Symbol

ESD

Common Point Ground

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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

Hindenburg disaster May 6, 1937

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Apollo 1 fire (ESD)

3 lives lost Jan 27, 1967

Manned Apollo flights

were suspended for 20 months

Virgil Grissom

Edward White II

Roger Chaffee

Identification

Elimination

Protection

Monitoring

Apollo 1 Accident

Short circuit in service Module's

number 2 oxygen tank (ESD)

April 13, 1970

No loss of life

Gordon Copper

Donn Eisele

Ed Mitchell

#2 Oxygen tank

Identification

Elimination

Protection

Monitoring

Apollo XIII Failure

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Anti-Static Bag

Anti-Static Tape Aircraft Static Discharger

Static Wrist Strap

ES

D P

ackagin

g &

Han

dlin

gE

SD

Pre

ventio

n

Identification

Elimination

Protection

Monitoring

Handling & Packaging

ESD Packaging, Handling and Prevention

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.

• I was a Licensed FAA Air Traffic

Controller in the United States Army

and worked on the Space Shuttle

Program, The International Space

Station Program, and the Ground

Missile Defense Program.

• Every job required Quality, whether

Air Traffic Control, Quality Inspection,

Quality Engineer, Systems Engineer,

Software Integration Engineer or

Task Leader.

• The following are some of the

elements of QUALITY that I

experienced: 28

DrawingsWork Ethic/ Honesty/Trust

Requirements

ComplianceCommunications Standards

Standards Customer SatisfactionHandbooks

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 and do the right thing even when no one is looking.

• All of these things are why I say that Quality is a Way of Life.

• Everyone is responsible regardless of your job title.

What is Quality to you?

What will be your story in 30 or 40 years?

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Backups

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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

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