Government-Industry Data Exchange Program GIDEP as a Resource

1. Government-Industry Data Exchange Program GIDEP as a Resource Presentation for the GSFC Systems Engineering Seminar, July 13, 2004 Presented by: Michael J. Sampson, Alert Coordinator Manager, Workmanship and EEE Parts Assurance NASA GSFC, Greenbelt, MD 20771 Code 306, Systems Management Office, Phone: 301-286-3335; Fax: 301-286-1667 Michael.J.Sampson@nasa.gov

2. Overview • Introduction to the Government-Industry Data Exchange Program (GIDEP) • Charter, Policy, History, Participation and Website • NASA and GSFC involvement • GIDEP Document Types • Including Examples • NASA and GSFC Processes for Handling GIDEP • NASA Advisories, differences from GIDEP • GIDEP and NASA Advisories as Lessons Learned Tools • Conclusions

3. GIDEP Mission Statement “The mission of the Government-Industry Data Exchange Program is to support government systems readiness, productivity and cost reduction through timely retrieval, storage and distribution of data among government and industry organizations.” Charter statement by the Department of Defense Joint Logistics Commanders

4. Office of Management and Budget Policy Letter No. 91-3 Reporting Nonconforming Products 4. Policy. Agencies shall review existing programs or, where necessary, establish new programs to assure the quality of purchased products and materials. Information shall be exchanged among agencies about nonconforming products. The existing Government/Industry Data Exchange Program (GIDEP)operated by the Department of Defense will serve as the central data base for receiving and disseminating information about such products.

5. GIDEP History • 1958 Army, Navy, Air Force Team established. Ballistic missile engineering data. • 1965-1966 NASA and Canada joined. Alerts introduced. • JLC Adopted Program and sponsorship. Naval Warfare Assessment Division lead. • OMB Policy Letter 91-3. Major Federal Agencies join. • On-line system introduced. Electronic distribution. • 1996 World-wide web access. • 1996 MIL-STD-1556B CANCELED! – Established REQUIREMENTS for contractor participation in GIDEP. MIL-HDBK-965 is replacement but only offers “Guidance”

6. GIDEP Community GIDEP is a partnership between Government Agencies and Industry teamed to share technically valid, fact-based information. The GIDEP community consists of approximately 400 Government and 1200 Industry Participants. Scientific and technical information is shared through an on-line web-enabled database.

7. GIDEP Sponsoring Agencies • US Army • US Navy • US Air Force • NASA • Department of Energy • Defense Contract Management Agency • Canadian Department of National Defence • Defense Logistics Agency

8. http://www.gidep.org

9. GIDEP ReportingHierarchy at GSFC OSSMA DIRECTOR W. Denoon Deputy – Systems Management R. Day Code 306 Chief W. Connley Alert Coordinator M. Sampson

10. NASA Documentation • NPR 8735.1A Procedures for Exchanging Parts, Materials, and Safety Problem Data Utilizing the Government-Industry Data Exchange Program and NASA Advisories. • Requires ALL NASA Centers Participate in GIDEP • AND Have a Process to Issue NASA Advisories • GPG 5340.3D Preparation and Handling of Alerts, Safe-Alerts and Advisories.

11. GIDEP Document Types:Alerts Alert: A GIDEP document that reports a problem with parts, components, materials, specifications, software, manufacturing processes, or test equipmentthat can cause a functional failure. Examples: • Cleanroom Wipes Contaminated With Silicones (September, 2003): The GSFC issued this Alert after receiving cleanroom wipes contaminated with silicones. At least one other government agency reported contaminated wipes from the same source. The responsible manufacturer reported that their supplier had provided contaminated raw material. • Semiconductor Device, Transistor, PNP, Silicon, Switching (May, 2004): A transistor exhibited an emitter-collector short due to a nickel particle.

12. GIDEP Document Types:Safe Alerts Safe-Alert: A GIDEP document that reports a non-conforming item, product or situation that creates a safety hazard for personnel or equipment.Examples: • Dynamometer (October, 2004): Dillon alerted customers that the Model AN and ANC dynamometers (used in overhead lifting) had a safety issue associated with fatigue life for units manufactured prior to and including 1978. Note: A total of seven affected dynamometers were found at GSFC/WFF and disposed of. • Stackable Side Chairs, Weld Failure (February, 2003): Two stackable metal frame chairs failed at the weld joint while personnel were sitting on them. For safety issues, contact Terry Spagnuolo (Code 250)Also, for safety issues involving non-conforming items, contact Mike Sampson (Code 306)

13. GIDEP Document Types:Safe Alerts Problem Advisory: A GIDEP document that reports a problem with parts,components, materials, manufacturing processes, specifications, software, manufacturing processes, or test equipment that has an unknown or low probability of causing problems for other users. Examples: • Zinc Whisker-Induced Failures of Electronic Systems (August, 2003): GSFC originated this Advisory with a special emphasis on facilities employing raised access floor systems comprised of zinc-plated floor tiles and or using a zinc-plated steel infrastructure. • Microcircuit, Hybrid, DC/DC Converter (August, 2003): The GSFC persuaded an OEM to issue an Advisory on a DC/DC converter that failed during GSFC ground testing in a vacuum environment. The failure was attributable to a solder joint.

14. 2003 - NASA GSFC Produced GIDEP ZINC Whiskers on Raised Floor Structures Zinc-Plated Steel Underside of Floor Tile It’s Growing ZINC WHISKERS!! Estimate 1 - 10 MILLION Whiskers on this Single Tile (4 sq ft area) Typical “Raised” Floor Computer Room

15. A Mechanism for Distribution of ZINC WHISKERS Throughout Raised Floor Facilities

16. GIDEP Document Types:Agency Action Notice Agency Action Notice: A GIDEP document that redistributes problem informationissued by a Government Agency to GIDEP participants. Examples: • CPSC, Central Sprinkler Company Update Voluntary Recall to Replace O-Ring Fire Sprinklers (May, 2003): The GSFC facilities group is in the process of replacing over 3,000 affected sprinkler heads that were found on Center. • Cylinder, Carbon Dioxide (January, 2002): The Defense Supply Center Philadelphia issued an alert against a manufacturer for defective carbon dioxide cylinders used on inflatable life vests and life rafts. Wallops found a total of 80 affected life vest cylinders and removed them from service.

17. GIDEP Document Types:Metrology Data Metrology Data: Consists of calibration procedures and technical manuals for various types of electronic/mechanical equipment. Calibration procedures provide instructions and information that enable calibration personnel to verify that instrument being calibrated is within prescribed tolerances. Technical manuals provide detailed maintenance, and/or repair/operating instructions. Examples: • The ICESat GLAS project requested and received a calibration procedure for a torque gauge GIDEP provides us with FAST access to Calibration and Tech Manuals that may otherwise be difficult to obtain.

18. GIDEP Document Types:DMSMS Data on Diminishing Manufacturing Sources and Material Shortages (DMSMS): Manufacturer data that provides occurrences of product and or product line discontinuances. Examples: • CZEM Switzerland: Discontinuance of Titanium Carbide Coating, Stainless Steel Balls Used in Precision Extreme Environment Ball Bearings: Two companies have partnered to purchase the process technology and transfer the equipment to the United States. • Aeroflex Laboratories: Notification to the Defense Supply Center and all customers that 11 SMD (“5962”) part numbers will be discontinued • Intel Product Discontinuance Notification 103986-00: Intel is announcing the discontinuance of Intel GDLXT12101. Product is discontinued from outsourced vendor (UMC). Final order date is June 30, 2005

19. GIDEP Document Types:Engineering Reports Engineering Reports: are technical papers on a variety of topics. Examples: • TRW’s Broadband Satellite Communication Payloads at C and KU Frequency Bands • Digital Signal Processing for Deep Space Transponders • Animation of Recorded Flight Data • Assessing the Risks of Commercial-Off-The Shelf Applications • Quick Prototyping of Flip Chip Assembly with MEMS • On-Chip 3D Air Core Micro-Inductor for High-Frequency Applications • Conformal coatings for 3D Multichip Microsystem Encapsulation

20. GIDEP Document Types:Reliability-Maintainability Reports Reliability-Maintainability Reports: are reliability-oriented technical papers on a variety of topics. Examples: • COTS Ceramic Chip Capacitors: An Evaluation of the Parts and Assurance Methodologies • Authored by Jay Brusse (QSS) at GSFC • Quality Control and Processing of Historical Oceanographic Temperature, Salinity, and Oxygen Data • Best Practice Reliability and Maintainability Standard • Best Practice Statistical Quality Control • Commercial Off-The-Shelf (COTS) Avionics Software Study

21. EOS AURA GIDEP Document Types:Urgent Data Requests Urgent Data Requests (UDRs) allow GIDEP participants to query information from the GIDEP Community. UDRs are often used to locate surplus parts that have been discontinued or locate parts that are critically needed for a given project. In addition, UDRs are used to solicit information such as failure data on EEE and mechanical parts. Examples: • Failure Rate, Failure Experience for Parts in TO Packages Assembled with 100% Nickel Caps. Failure mode is shorts caused by nickel flake particles. • Failure experience with wirewound resistors. Failure mode is intermittent or catastrophic open due to weld failure or related wire breakage • Source of Supply Request for CPU Module • Failure Experience, Failure Mode for Transistor

22. GIDEP Document Types:Product Change Notices Product Change and Product Information Notices: provide respective data on product changes (i.e. datasheet, facility relocations) and product information (i.e. test data, Qualified Manufacturer List status, and package types). Examples: • Micron Product Change Notification PCN1436-PPS2K: To announce the minimum number of packaged parts shipped on a tape-and-reel carrier will change from 1,000 devices to 2,000 devices. • Xilinx Advanced Product Change Notification PCN2003-04: Additional wafer fabrication facility for the C-grade members of the XC18V00 family of the In-System Programmable Configuration PROMs.

23. GIDEP Document Types:Lesson Learned Bulletins Lessons Learned: provide work experiences on a variety of subject matter. Sharing adverse experiences may help avoid recurrences. Examples: • Warning: Hotels Could Be Hazardous To Your Health • Graduate Student Incurs Laser Injury to Eyes • Damage to Overhead Power Lines by 90-Ton Crane • Failure of the Finnigan Triton Mass Spectrometer • Zinc Whisker Shorting in Vacuum

24. Warning: Hotels Could Be Hazardous To Your Health • You open the door to your hotel room and drop your luggage. AT THAT VERY MOMENT, turn around and go back into the hallway to check your exit!!! Talk it over as you walk toward it. Is it on the left or right … do you have to turn a corner? Open the exit door … what do you see … stairs or another door? Count the number of rooms/doors you go by to get to the exit! As you arrive back to your room, take a look once more. Do you think you could get to the exit with a blindfold on? You better be able to, because smoke is a deadly blindfold!!! During a fire, a well planned exit strategy can save your life! • The procedure takes less than one minute to be effective. It must become a habit!!!! Those of you who are too lazy or tired to do it are real “riverboat gamblers”. There are over 5,000 hotel fires per year. The odds are sure to catch up with you. • You must know how to avoid smoke and panic to survive a hotel fire!!!

25. Access to GIDEP Documents Due to ITAR restrictions, you must be a US citizen in order to be granted database accessibility • Currently, GIDEP documents can be viewed either by: • Registering as a GIDEP User in order to access the GIDEP database. See the Alert Coordinator for form. • Subscribing to the OSSMA GIDEP Alert/NASA Advisory distribution system. Contact the Alert Coordinator in order to be placed on email list.

26. GIDEP Distribution Restrictions • Per the GIDEP Manual, “Information distributed by GIDEP contains technical data whose export is restricted by Arms Export Act (Title 22, USC Sec. 2751 EtSeq) or Executive Order 12470.” • In addition, GIDEP documents have the following distribution restriction: “Distribution is not authorized outside of the GIDEP participant’s organization.”

27. Incoming GIDEP Document Process • Per NPR and GPG requirements, an engineering review of the following documents is performed: Alerts, Safe-Alerts, Problem Advisories, and Agency Action Notices. In addition, NASA Advisories are reviewed. • Based on review, the documents are distributed as appropriate. • Project (or affected Code) responses are required and documented in GSFC closed loop system

28. Log of Incoming Alerts and Advisories (Sample Only)

29. Project Summary Metrics

30. Creating GIDEP Alerts andNASA Advisories • Candidates for GIDEP Alerts and NASA Advisories are reviewed by the Office of the Alert Coordinator • NASA Advisory: A NASA document for exchanging significant parts, materials, and safety problems or concerns among NASA activities • Used for NASA-specific and NASA-caused errors and lessons learned • Or when a GIDEP is not possible or practical • Or to address spaceflight specific implications of others’ experiences • The Office of the Alert Coordinator provides technical writing and content support to the Technical Point of Contact • The Chief Counsel reviews all NASA Advisories for legal issues and for unrestricted distribution

31. Examples of GSFC NASA Advisories in 2004 • NA-GSFC-2004-08 Testing of Actel SX-A and RTSX-S Programming Algorithms • NA-GSFC-2004-07 Thruster (1.0 lbf) Assembly Failure • NA-GSFC-2004-06 Actel RTSX-S and SX-A Programmed Antifuses • NA-GSFC-2004-05 Cable Failure Attributable to Workmanship Error During Assembly of COTS Connector • NA-GSFC-2004-04 TRST* and the IEEE JTAG 1149.1 Interface. FPGAs • NA-GSFC-2004-03 Unauthorized Distributors • NA-GSFC-2004-02 Application Concerns on COTS MOSFETS from International Rectifier • NA-GSFC-2004-01 Indium Solder Encapsulating Gold Bonding Wire Leads to Fragile Gold-Indium Compounds and an Unreliable Condition that Results in Wire Interconnection Rupture

32. Indium Gold Compounds on GLAS Diode Array From NASA Advisory NA-GSFC-2004-01 Gold Wire Becomes Fragile And May Rupture Indium Solder + Gold Wires = Reliability Hazard!!! Indium Gold Intermetallic Gold Wire Lesson: Avoid use of Indium in Proximity to Gold !!!

33. Lessons Learned • Alerts and Advisories are VERY Effective Methods for Communicating Lessons Learned • Disposition is Usually Contractually Imposed • Most Contractors are Long-Time Participants and Have Well-Developed Response Processes • Market Recognition • Well-Developed NASA Closed Loop Process

34. In conclusion, GIDEP is a Resource • Alerts, Safe-Alerts, Advisories, and Agency Action Notices are free.These documents are very helpful in ensuring mission success • GSFC NASA Advisories are freely distributed with no distribution restrictions. GSFC NASA Advisories capture valuable Lessons Learned • Obtain free calibration reports to maintain equipment calibration • Engineering and Reliability-Maintainability reports are available • Utilize Urgent Data Requests to locate surplus parts and materials • Urgent Data Requests also can be used to request failure experience data • Free reports are also available on Lessons Learned, DMSMS, and Product Change and Product Information Notices

35. The Alert Process is Two-Way • Almost Every Project in NASA Will Benefit from the Information Provided by GIDEP Documents and NASA Advisories • We Have A Legal and Ethical Requirement to Contribute Our Lessons Learned • So Please Do Your Part and Report Candidate Incidents or Experiences • We Will Make it Easy