Code 300 Overview Code 300: Workmanship

1. Code 300 OverviewCode 300: Workmanship Name: Jeannette Plante Title: Project Lead Office: Bldg 15, Rm 213 Tel: 4-5944 Email: jeannette.f.plante@nasa.gov

2. Soldering Polymeric applications Cable harnesses Fiber Optic cables

3. Example of Defects - Soldering Excessive Solder Bridging Solder Insufficient Solder

4. Example of Defects - Soldering Flux Residue Incomplete solder flow Burned Flux and flux residue Gold Embrittlement

5. Fractured solder joint Excess staking Excess solder bridging terminals

6. Example of Defects – Cables and Harnesses Typical Harness Installation Unacceptable Harness Installation Bent Connector Pins Flux residue/corrosion byproduct

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.

8. Electrostatic Discharge Damage

9. Organization Charter Provide engineering and assurance expertise for printed wiring assembly and cable harness assemblyprocesses that are used in the manufacturing of electronic hardware for space flight application. • 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 • Provide support to OSMANASA 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

10. Who are the Workmanship Group? Jeannette Plante – Manager, Policy lead, SME support Bob Humphrey – SME support, Soldering, Cables, Level A Instructor Jose Sancho – SME support, ESD Bench Certifier, ESD Control Expert Rigo Garcia – SME support, Residues/Cleaning, GSFC Manufacturing Guidelines, ESD Bench Certifier Bob 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 Instructor Riley Northam – Level A Instructor Vacant – Level A Instructor Elaine Hill - Registrar

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.)

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?

13. NASA Documents Managed by the Workmanship Group Cancelled for new projects

14. Candidate Voluntary Consensus Standards for NASA Adoption • 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 Adopted by NASA on 10/17/2011

15. Websites Maintained by Workmanship for Agency http://nepp.nasa.gov/workmanship https://nsckn.nasa.gov/workmanship

16. GSFC Documents Managed by the Workmanship Group 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

17. Websites Maintained by Workmanship for Agency http://sma.gsfc.nasa.gov/workmanship

19. Example of a Page from GSFC-STD-6000

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

21. Special Process or Non-Standard Configuration Any configuration outside of the scope of the Workmanship Standards needs: Declared in advance Reliability 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.

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: 19 Boeing: 1 Emcore: 1 GSFC: one in process L3: one in process SEAKR: 2 Moog: 1 Workmanship recommends or does not recommend approval to the CSO. Categories are: Recommend without conditions Recommend with conditions Not recommended for use Requires MRB approval Inconclusive Withdrawn Recommendation is Project-specific Project makes final determination

23. Design and Processing Requirements The Use of Jumper Wires (“White Wires”) Pre-CDR Requires Code 300 Chief Engineer Review/Approval Excessive jumpers indicates a redesign that invalidates “heritage”

24. QUESTIONS?