G O D D A R D S P A C E F L I G H T C E N T E R Code 300 Overview Code 300: Workmanship Name:Jeannette Plante Title:Project Lead Office:Bldg 15, Rm 213.

G O D D A R D S P A C E F L I G H T C E N T E R

Code 300 Overview

Code 300: Workmanship

Name: Jeannette PlanteTitle: Project LeadOffice: Bldg 15, Rm 213Tel: 4-5944Email: [email protected]

G O D D A R D S P A C E F L I G H T C E N T E R 2

SolderingPolymeric applicationsCable harnessesFiber Optic cables

G O D D A R D S P A C E F L I G H T C E N T E R 3

3

Example of Defects - Soldering

Insufficient Solder

Excessive Solder

Bridging Solder

G O D D A R D S P A C E F L I G H T C E N T E R 4

4

Burned Flux and flux residue

Incomplete solder flow

Gold Embrittlement

Example of Defects - Soldering

Flux Residue

G O D D A R D S P A C E F L I G H T C E N T E R 5

Excess solder bridging terminalsExcess staking

Fractured solder joint

G O D D A R D S P A C E F L I G H T C E N T E R 6

6

Typical Harness Installation Unacceptable Harness Installation

Flux residue/corrosion byproductBent Connector Pins

Example of Defects – Cables and Harnesses

G O D D A R D S P A C E F L I G H T C E N T E R 7

7

Cab le insulation stressed by compression of less than minimum bend radius

Cable insulation stressed by sharp edge

Single indenter crimp does not provide gas-tight crimp and leads to cracks in contact crimp barrel.

G O D D A R D S P A C E F L I G H T C E N T E R 8

Electrostatic Discharge Damage

G O D D A R D S P A C E F L I G H T C E N T E R 9

Organization Charter

Provide engineering and assurance expertise for printed wiring assembly and cable harness assembly processes that are used in the manufacturing of electronic hardware for space flight application.

Provide support to OSMA NASA HQ - Maintain five NASA-STD-8739 requirements documents.

- Maintain NASA-adopted VCS’s- Help resolve Agency-level waiver requests

- Help resolve Agency-level audit findings

- Keep Western and Eastern Training Centers aligned with policy

GSFC Project Support

- Help resolve non-compliances in flight hardware

- Resolve assurance rules for new and non-standard assembly methods

GSFC Lab Processes

- Manage GSFC ESD Control Program

- Capture and share GSFC Packaging Rules and Best Practices

- Implement Workmanship Stds in GSFC Labs

G O D D A R D S P A C E F L I G H T C E N T E R 10

Who are the Workmanship Group?

Jeannette Plante – Manager, Policy lead, SME supportBob Humphrey – SME support, Soldering, Cables, Level A InstructorJose Sancho – SME support, ESD Bench Certifier, ESD Control ExpertRigo Garcia – SME support, Residues/Cleaning, GSFC Manufacturing Guidelines, ESD Bench CertifierBob Esser – SME support, ESD Control Lead, GSFC Manufacturing Book

Vacant – ESD Bench Certifier at WFF

SME = Workmanship Subject Matter Expert Support to Projects

Who are the Training Center?Felix Frades – Level A InstructorRiley Northam – Level A InstructorVacant – Level A InstructorElaine Hill - Registrar

G O D D A R D S P A C E F L I G H T C E N T E R 11

When to Call the Workmanship Group

• How do I specify Workmanship requirements in my MAR?• My supplier wants to use a non-standard configuration, what

rules apply?• What electrical tests are required for workmanship acceptance

of a wire harness?• I’m not sure that this vendor has a controlled soldering process,

can someone take a look at it?• The project needs to start work on an ESD-sensitive item, how

do we get the bench certified?• During Workmanship inspection we found something unusual,

what might be the cause of this artifact? Is it a defect?

Projects need to Budget 0.1 – 0.2 FTEs for Workmanship per year. More if new technologies are expected (CGA, Water Soluble Flux, Pb-free Solder, etc.)

G O D D A R D S P A C E F L I G H T C E N T E R 12

When to Call the Reliability Group• The supplier has designed and built a non-compliant

configuration. • Will it survive the mission?• Is the qualification data sufficient?• What is the risk to the mission?

• What tests should the supplier run to qualify a non-standard configuration?

Workmanship provides historic, best-practice based inspection rules for established technologies.

The developer (supplier) has to define inspection criteria for interconnects which are out of scope. This criteria should be based on what is “normal” for the controlled process and what the qualification testing says will survive the mission.

Workmanship rules are not used to predict reliability. Workmanship rules are used to assess quality: did the process produce what was expected?

G O D D A R D S P A C E F L I G H T C E N T E R 13

NASA Documents Managed by the Workmanship GroupTitle Number

Workmanship Standard for Polymeric Application on Electronic Assemblies NASA-STD 8739.1

Workmanship Standard for Surface Mount Technology NASA-STD 8739.2

Workmanship Standard for Soldered Electrical Connections NASA-STD 8739.3

Workmanship Standard for Crimping, Interconnecting Cables, Harnesses, and Wiring NASA-STD 8739.4

Workmanship Standard for Fiber Optic Terminations, Cable Assemblies, and Installation NASA-STD 8739.5

Standard for the Development of an ESD Control Program for the Protection of Electrical and Electronic Parts, Assemblies,

and Equipment (Excluding Electrically Initiated Explosive Devices)

ANSI/ESD S20.20

Space Applications Electronic Hardware Addendum to J-STD-001E Requirements for Soldered Electrical and Electronic

Assemblies

IPC J-STD-001ES

Workmanship Manual for Electrostatic Discharge Control (Excluding Electrically Initiated Explosive Devices) NASA-HDBK-8739.21

Implementation Requirements for NASA Workmanship Standards NASA-STD-8739.6

Cancelled for new

projects

G O D D A R D S P A C E F L I G H T C E N T E R 14

J-STD-001ES Space Applications Electronic Hardware Addendum to J-STD-001E Requirements for Soldered Electrical and Electronic Assemblies

IPC/WHMA-A-620AS, Space Applications Electronic Hardware Addendum to IPC/WHMA-A-620A Requirements and Acceptance For Cable and Wire Harness Assemblies

Candidate Voluntary Consensus Standards for NASA Adoption

Adopted by NASA on 10/17/2011

G O D D A R D S P A C E F L I G H T C E N T E R 15

Websites Maintained by Workmanship for Agency

http://nepp.nasa.gov/workmanship

https://nsckn.nasa.gov/workmanship

G O D D A R D S P A C E F L I G H T C E N T E R 16

GPR 8730.6 GSFC Policy for Electrostatic Discharge, 6/7/10

GSFC-WM-001B Workmanship Manual for Electrostatic Discharge Control (Excluding Electrically Initiated Explosive Devices), 7/10/2008

Not Numbered GSFC Electronic Assembly Manufacturing Requirements and Best Practices, 10/7/11

GSFC-STD-6001 Ceramic Column Grid Array Design and Manufacturing Rules for Flight Hardware, Rev-, 2/22/11

300-WI-8730.6.1 Assessment Plan for Ceramic Column Grid Array (CCGA) Attachment Process, 1st Draft, 7/22/10

300-WI-8730.x.x ESD Bench Certification Process, in process

Not Numbered NASA-GSFC Workmanship Requirements For Water Soluble Flux Assurance, Rev A, 11/10/10

GSFC Documents Managed by the Workmanship Group

G O D D A R D S P A C E F L I G H T C E N T E R 17

Websites Maintained by Workmanship for Agency

http://sma.gsfc.nasa.gov/workmanship

G O D D A R D S P A C E F L I G H T C E N T E R 18

G O D D A R D S P A C E F L I G H T C E N T E R 19

Example of a Page from GSFC-STD-6000

G O D D A R D S P A C E F L I G H T C E N T E R 20

Procedure: Step-by-step instructions for implementing a manufacturing process. Procedures will include steps that ensure that quality requirements are met.

Requirement Document: Collection of requirement with applicable scope and intended requirements owners. May include accept/reject/defect criteria.

Workmanship Standards are Requirements Documents

Supplier Procedures are not substitutes for NASA’s requirements documents.

Exceptions taken to NASA’s requirements must be declared in advance by the supplier and not discovered later by CSO in a procedure.

Justification would include assurance requirements to be used.

Can the supplier use their own procedures instead of the Workmanship Standards?

G O D D A R D S P A C E F L I G H T C E N T E R 21

Any configuration outside of the scope of the Workmanship Standards needs:

Declared in advanceReliability data for relevant environment (i.e. life test)Custom quality criteria – Workmanship standards inspection rules may not be suitable.Approved in advance

Examples: Lead-free solder, organic acid flux, ball grid array, >5 wires in a crimp splice, dead-bug mounting, leads without stress relief

Caution: Some suppliers call their own internal process engineering testing “Qualification”. NASA calls life-testing “Qualification”. Supplier’s claims that a non-standard process or configuration is “qualified” may not meet the intent of the Workmanship requirement.

Caution: Some suppliers consider their “special” processes to be “standard”. Our definition is relative to the scope of the Workmanship Standard. Outside the scope = non-standard.

Special Process or Non-Standard Configuration

G O D D A R D S P A C E F L I G H T C E N T E R 22

“GSFC already approved this process”

Workmanship has created a method for reviewing non-standard supplier processes or configurations. Many of these are “standard” to the supplier and show up across projects. Our method helps reduce repetitive reviews and makes our response more consistent.

Supplier Non-standard Processes Currently on File:

BAE Systems: 2 (one more in process)Ball Aerospace: 19Boeing: 1Emcore: 1GSFC: one in processL3: one in processSEAKR: 2Moog: 1

Workmanship recommends or does not recommend approval to the CSO.

Categories are:Recommend without conditionsRecommend with conditionsNot recommended for useRequires MRB approvalInconclusiveWithdrawn

Recommendation is Project-specificProject makes final determination

G O D D A R D S P A C E F L I G H T C E N T E R 23

23

Design and Processing RequirementsThe Use of Jumper Wires (“White Wires”) Pre-CDR Requires Code 300 Chief

Engineer Review/Approval

Excessive jumpers indicates a redesign that invalidates “heritage”

G O D D A R D S P A C E F L I G H T C E N T E R 24

12/2/2009 24

QUESTIONS?