Professional Documents
Culture Documents
July 1999
Agenda
Background
Design Overview
Maintenance Drivers
Factors Affecting Cost
Materials
Access
Touch Time Labor
Costs per TPS Type
Off Line Support
Improvements To Reduce Cost
Presently In-work
Future Necessities
Beyond Shuttle
2
TPS Surfaces
Lower Surface
Upper Surface
TPS Legend
HRSI (Black) Tiles
LRSI (White) Tiles
AFRSI Blankets
FRSI
RCC
Glass
Exposed Metallic Surfaces
Tile Configuration
Gap
Step
Koropon-Primed
Structure
Uncoated Tile
Filler Bar
Coating Terminator
Quartz
OML Fabric
Quartz
OML
Thread
A
Quartz Batting
B
OML
Thread
View B-B
OML Fabric
Folded Over
To IML and
Stitched
Through
Thickness
C
Section A-A
OML
Thread
Glass IML
IML
Fabric
Thread
View C-C
OML Thread
OML Thread
Batting
OML
Fabric
IML Thread
IML
fabric
IML Fabric
E
Section D-D
Glass IML
Thread
Detail E
A
A
E
HRSI Tiles
Section A-A
Interface Gap
Between
RCC and
HRSI Tiles
Section C-C
Detail D
Section B-B
Upper LESS
Access Panel
HRSI Tiles
RCC
Tee Seal Web
(In Background)
Thermal Barrier
I nconel
Attachments
C
Upper
Left
Wing
ACSS Hardware
C
RCC Panel
(In Foreground)
I nconel
Insulators
Wing Spar
Lower Wing HRSI Tile
Horsecollar
Peripheral Gap Filler
Section E-E
Gap Fillers
Nextel Ceramic Fabric
Saffil Alumina Batting
Saffil Alumina
Batting
Inconel Foil
Inconel Foil
Nextel Sleeving
Saffil Alumina
Batting
Inconel Foil
Pillow Captive Type
(Double Lip)
Inconel Foil
Pillow Captive Type
(Single Lip)
Ames Type
Crew Hatch
Vent Doors
10
11
Aerothermal Seals
A
Wing/Elevon
Uncoated AFRSI
Blankets
Hinge
Pins
Lower Elevon
TPS
0.5
Gap
Spanwise Polyimide
Primary Seal
Orbiter TPS
~20
~75
306 (8 lb)
2,123 sq ft
2,024 sq ft
TOTAL IMPACTS
STS-41D/FL1
30
111
STS-51A/FLT2
20
87
STS-51C/FLT3
28
81
STS-51D/FLT4
46
152
STS-51G/FLT5
144
315
STS-51I/FLT6
33
141
STS-26R/FLT7
55
411
STS-29R/FLT8
23
132
STS-33R/FLT9
21
118
STS-31R/FLT10
14
63
STS-41/FLT11
16
76
STS-39/FLT12
16
237
STS-48/FLT13
25
182
STS-42/FLT14
44
209
STS-53/FLT15
23
240
STS-56/FLT16
36
156
STS-51/FLT17
18
154
STS-60/FLT18
15
106
STS-64/FLT19
19
150
STS-63/FLT20
14
125
STS-70/FLT21
127
STS-82/FLT22
18
103
STS-85/FLT23
102
STS-91/FLT24
50
198
STS-95/FLT25
45
187
OV-103 AVERAGE
30.7
158.5
FLEET AVERAGE
31.1
149.2
Materials Cost
Raw Materials*
$200k / Flight
Tile PUs
$137k / Flight
Consumables
$ 10k / Flight
Total
$347k / Flight
Work Access
Access
21.83%
Out-of-Tolerance
6.34%
Ground Handling
5.63%
Flight
33.80%
Modification
32.39%
TPS Discrepancies
FRSI, Filler Bar,
and All Others
3.56%
Gap Fillers,
Thermal Barriers,
and O/T Conditions
16.30%
FI Blankets 3.50%
Re Water
Proofing
2.88%
RSI Tiles
73.75%
Complex NC
25.29%
Complex Splash
Tile 7.79%
FRSI 0.20%
Simple NC
Tile
35.02%
1
Complex NC Tile
No Rework NC Tile
Reinstall Tile
Row Time
FRSI
Touch Labor
Simple FI Blanket
175
150
125
100
75
50
25
Complex FI Blanket
MDR Repairs
14.27%
ML0601
Repairs
10.71%
ML0601-9025
Repairs
12.03%
Removals &
Replacements
55.70%
Tile
= 2.27 hours/sq.ft.
FIB
= 0.16 hours/sq.ft.
FRSI
= 0.02 hours/sq.ft.
Discipline Comparison
Quality Assurance
15%
Operations 8%
Logistics 3%
Engineering
18%
Maintenance
Technicians
37%
Manufacturing
Technicians
19%
2
OPF Processing
Orbiter Landing at KSC, Tow to OPF, Jack and Level
PLBD Strong back Installation, PLBD Open Up
TPS Post Flight Inspection
TPS Waterproofing
TPS Processing
Payload Removal
Payload Bay Reconfiguration
FRCS Functional
SSME Heat Shield Removal
SSME Removal
OMS Pod Functional
Hydraulic System Fill and Bleed Removal Aerosurfaces
Fuel Cell Voltage Test
Payload Premate Testing
Drag Chute Installation
APU Servicing and Checkout
Payload Bay Cleaning
Payload Installation
SSME Installation
All Closeouts
TPS Operations
SSME/MPS Ops
Payload Ops
Vehicle Ops
1 Week
TPS Workforce
BNA-Downey
Pre USA TPS
Organization
USA-JSC / BNA-Houston
NASA-JSC
Latest TPS
Organization
25
50
75
100
125
150
175
Personnel
178
47
33
31
8
4
3
16
95
23
5
6
4
15
4
5
13
490
Personnel
100
32
34
7
3
1
1
10
52
11
3
13
4
5
6
3
1
32
318
2
Presently In-work
Processing Reductions
Less Toxic Re-Waterproofing
Surface Defect Analyzer
Future Improvements
White TUFI
Ceramic Captive G/F
Thermal Barrier Improvements
Beyond Shuttle
No Penetrations
No Windows
Self Healing TPS