1、Public Lessons Learned Entry: 3016 Lesson Info: Lesson Number: 3016 Lesson Date: 2010-04-19 Submitting Organization: KSC Submitted by: Annette Pitt Subject: Component Barcoding and Tracking Systems Abstract: The processing of flight hardware requires the ability to track and account for thousands of
2、 individual parts in real time. Faster, more accurate processing and documentation can be achieved by applying a unique and intelligent bar-code label to each part, and tracking the parts in a central database. Travelers/part tags can be machine-printed and attached to parts so they can be tracked a
3、s they are removed, inspected, stored, recalled, and reinstalled. Description of Driving Event: During return-to-flight processing for STS-26R, STS-27R, and STS-28R in the late 1980s, a huge number of Thermal Control System (TCS) components were removed from each vehicle. During this time, the misre
4、ading of part IDs resulted in numerous problem reports, time-consuming paperwork, and lost man-hours to correct the discrepancies. This occurred in 10 to 20 percent of all TCS removals. To deal with this problem, in 1989 the TCS tracking system was put into use under the Shuttle Processing Data Mana
5、gement System II (SPDMS2). It was enhanced in 1992 to support the first Orbiter Maintenance Downtime Period (OMDP) for the Shuttle Orbiter Discovery (OV-103) at KSC and reduced processing rates to 33 TCS blankets in 15 minutes, with a program savings estimated at $90K per flow. In 2006, a conversion
6、 from the LSOC1 program to Oracle brought many more enhanced features. This upgrade was a catalyst for improving the tracking and status features of other systems, such as the Carrier Panel Tracking System. This single program greatly enhanced processing of over 35,000 parts in the TCS inventory, bo
7、th in the vehicles and in Logistics. The bar coding of parts and their locations prior to removal saves time and money and is a user-friendly system for shop employees, planner/schedulers, and managers. Lesson(s) Learned: The discrepancies noted during return-to-flight processing included difficulty
8、 in producing a legible ID with rubber stamps and ink; illegible part/serial/order control numbers; human error in reading part/serial/order control numbers whether legible or not; and human error in transcribing part/serial/order control numbers onto paperwork. Other problems were noted, including
9、time-consuming efforts in inventory control and reporting functions; mundane repetitive accountability procedures; the need for more stringent requirements for accuracy and quality control; and problems with configuration control and documentation control. The lesson learned from this experience was
10、 that entering data by visual observation and handwritten entries produced numerous errors; but by bar-coding parts, a database can be built and used for easy processing of thousands of parts. Travelers can be printed with preloaded information from the database in lieu of making visual observations
11、 and hand entries. Some advantages gained from bar coding and tracking were; Reduced cost (fewer installation mistakes per configuration and fewer installation man-hours) Improved accountability of hardware from removal through installation during processing (better logistic accountability and elimi
12、nation of delays for configuration verification) Improved installation of parts (for multiple items) by bar-coding the part and its location with the same bar code number Improved efficiency rather than being retrieved from a random handwritten log, with the Parts To Go function, parts can be retrie
13、ved from a sorted list (arranged by vehicle zone, installation drawing, or any manner the technician might choose) Reduced need for paperwork to correct configuration discrepancies (errors in entering, reading, or transcribing part/serial/order control numbers) Reduced human error (in installation,
14、reading ID labels, location, storage, and typographical errors) Use of common software to support both the TCS tracking system and Carrier Panel Tracking System. Recommendation(s): Future systems would benefit from adopting this same approach to processing. One central database can be used for a ref
15、erence file, loaded with all the information needed to properly process (remove, inspect, store, recall, install) each part. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Evidence of Recurrence Control Effectiveness: Under the new TCS tracking syst
16、em, the Configuration Discrepancy Report count became zero for misread or incorrectly documented part/serial/order control numbers. There were almost no mislocated parts, and paperwork was less cluttered. Documents Related to Lesson: Click here to download “How The Tracking System Works” document Mi
17、ssion Directorate(s): Space Operations Exploration Systems Additional Key Phrase(s): 0.Ground Operations 0.Parts, Materials, & Processes 1.Configuration control and data management 0.Packaging, Handling, Storage 0.Configuration Management 1.Ground processing and manifesting Additional Info: Project: Flight hardware processing of multiple parts. Approval Info: Approval Date: 2010-08-09 Approval Name: mbell Approval Organization: HQ Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
