Product Assurance

ZIN Technologies’ Product Assurance activities encompass the following disciplines:

• System Safety
• Materials and Processes
• Electrical, Electronic and Electromechanical (EEE) and Mechanical Parts
• Reliability, Maintainability and Availability
• Quality Assurance
• Software Assurance

System Safety

Implementation of the system safety process for space flight payloads begins with a detailed knowledge of pertinent payload safety requirements, which flow down a documentation hierarchy that begins with NSTS 1700.7, Safety Policy and Requirements for Payloads using the Space Transportation System and NSTS 1700.7B, ISS Addendum, Safety Policy and Requirements for Payloads Using the International Space Station.

For ground processing at KSC, pertinent safety policies and requirements are specified in KHB 1700.7, Space Shuttle Payload Ground Safety Handbook. Other requirements documents that must be considered during the payload safety review process include, but are not limited to NSTS/ISS 13830, Payload Safety Review and Data Submittal Requirements and NSTS/ISS 18798, Interpretation of NSTS/ISS Payload Safety Requirements.

ZIN Technologies has successfully guided many space flight payloads through NASA’s system safety process, including:

• Identification of hazards and related hazard controls.
• Preparation of safety data packages.
• Conducting phase safety reviews with NASA’s Payload Safety Review Panel.
• Completion of the safety verification process.

Materials & Processes

The objective of the materials and processes (M&P) function is to ensure that materials selected for use in space flight payloads meet pertinent safety requirements. This is accomplished through the proper selection, processing, inspection/testing and evaluation of the chosen materials. Materials are evaluated in their usage environment for the following, as appropriate:

• Stress corrosion cracking resistance.
• Corrosion resistance.
• Flammability – based on oxygen concentration.
• Offgassing (toxicity)
• Outgassing (thermal vacuum stability)
• Fungus resistance
• Fluid system compatibility

Materials ratings are obtained from NASA’s Materials and Processes Technical Information System (MAPTIS) and recorded in a Materials Identification and Usage List (MIUL). Material Usage Agreements (MUAs) are prepared for materials that are not A-rated in their usage environment. Material testing is coordinated with NASA’s testing facilities, as appropriate.

Electrical, Electronic and Electromechanical (EEE) and Mechanical Parts

EEE parts selections are driven by the performance demands, environmental and circuit application, reliability (necessary for the satisfactory performance of the systems in which they are used) and maintenance allocations defined by the equipment specification. Proper controls or design alternatives are established to eliminate part level failures in the worst case circuit application over the required operational life defined by the equipment specification. Steps are taken to reduce the risk or impacts of a part level failure.

EEE parts are selected based on the suitability for their applications and proven qualifications (by test or similarity) to the requirements of their specifications. Selections minimize the number of styles and generic types. Parts with proven technologies and with inherent reliability features are preferably selected. EEE parts selections are recorded in an EEE Parts List. EEE parts stress analyses provide sufficient data to verify EEE parts are adequately de-rated to insure long term reliability, and are not overstressed in worst case environments, operating conditions and duty cycles.

Mechanical parts, e.g. fasteners, bearings, etc. are similarly controlled, as appropriate. Mechanical parts selections are recorded in a mechanical parts list. Mechanical parts applications are nominally evaluated as part of the overall structural design process.

Reliability, Maintainability and Availability

Reliability and Maintainability directly impact mission effectiveness in terms of equipment availability, as failed equipment cannot support mission requirements. Reliability and Maintainability analyses provide a cost effective means of optimizing the design to provide the needed reliability, maintainability and availability for supporting mission requirements. Various analyses performed in support of the design include:

• The Reliability Prediction provides a figure of merit on the hardware design, which can be compared to design requirements.
• The Maintainability Prediction provides an estimate of repair time for hardware based on design, test criteria, availability of needed replacement items and remove/replace times.
• The Availability Analysis estimates equipment availability based upon reliability and maintainability criteria.
• The Failure Modes, Effects and Criticality Analysis provides the effects of part failure on the mission and highlights critical effects so that corrective action may be taken to mitigate or eliminate hazards.
• Reliability/Maintainability Trade Studies provide a cost-effective means of meeting mission requirements.
• Operation and Maintenance Support Analysis provides information of various means of supporting the hardware and the impact on equipment availability.

Quality Assurance

ZIN Technologies’ Quality Management System meets the requirements of ANSI/ISO/ASQ Q9001-2000, Quality Management Systems – Requirements. The Quality System was originally registered on March 15, 2001 to the 1994 version of the standard and was subsequently transitioned to a Quality Management System on January 6, 2004. ZIN Technologies’ Quality Management System is currently registered by AQA International, LLC (certificate no. 4335).

The success of the Quality Management System is evidenced by the success rate of the on-orbit payloads (100%) and customer acceptance during Pre-Ship Reviews. The Quality Management System retains flexibility for the specific requirements and complexities of individual projects.

Specific Quality Plans are developed for space flight payloads to ensure that:

• Completed Payloads operate successfully and achieve performance specifications.
• The design is documented by drawings, schematics and bills of material with sufficient description to enable the procurement of items and the preparation of assembly, inspection and test procedures.
• Instructions for receiving inspection, assembly, in-process inspections, testing, packing and shipping are recorded and followed.
• Labeling, serial numbers, model numbers and documentation are completed at each stage of manufacturing so that traceability is maintained.
• Product defects, non-conformances and failures are recorded and reviewed for closed-loop corrective action.
• Equipment and devices used for measurement as a part of assembly, inspection and/or testing are calibrated according to an established schedule, and that calibrated equipment and devices are used for product verification/validation activities.
• All non-conforming (rejected) materials, parts, components or software are segregated from conforming product, and controls are in place to prevent rejected products from being used.
• Workmanship standards are identified and followed.
• Appropriate configuration management practices are in place to assure adequate control of all hardware, software and associated records.

Software Assurance

From the time software selections are made and designs are begun, software assurance activities are included in the life cycle of the product. Using NASA standards for Software Assurance and the Capability Maturity Model of the Software Engineering Institute, ZIN Technologies develops and documents the software components of every project. Experience with NASA payloads and requirements have led to the development of considerable expertise in:

• Conducting effective inspections, reviews and audits.
• Creating the most effective test strategies for projects of varying complexity.
• Managing and executing system, functional and regression tests.
• Creating simulators and process test beds for real-time embedded systems.
• Running an effective configuration management system for software.
• Planning for the life of the software after deployment.