NASA Planning for Orion Multi-Purpose Crew Vehicle Ground Operations

The NASA Orion Ground Processing Team was originally formed by the Kennedy Space Center (KSC) Constellation (Cx) Project Office's Orion Division to define, refine and mature pre-launch and post-landing ground operations for the Orion human spacecraft. The multidisciplined KSC Orion team consisted of KSC civil servant, SAIC, Productivity Apex, Inc. and Boeing-CAPPS engineers, project managers and safety engineers, as well as engineers from Constellation's Orion Project and Lockheed Martin Orion Prime contractor. The team evaluated the Orion design configurations as the spacecraft concept matured between Systems Design Review (SDR), Systems Requirement Review (SRR) and Preliminary Design Review (PDR). The team functionally decomposed prelaunch and post-landing steps at three levels' of detail, or tiers, beginning with functional flow block diagrams (FFBDs). The third tier FFBDs were used to build logic networks and nominal timelines. Orion ground support equipment (GSE) was identified and mapped to each step. This information was subsequently used in developing lower level operations steps in a Ground Operations Planning Document PDR product. Subject matter experts for each spacecraft and GSE subsystem were used to define 5th - 95th percentile processing times for each FFBD step, using the Delphi Method. Discrete event simulations used this information and the logic network to provide processing timeline confidence intervals for launch rate assessments. The team also used the capabilities of the KSC Visualization Lab, the FFBDs and knowledge of the spacecraft, GSE and facilities to build visualizations of Orion pre-launch and postlanding processing at KSC. Visualizations were a powerful tool for communicating planned operations within the KSC community (i.e., Ground Systems design team), and externally to the Orion Project, Lockheed Martin spacecraft designers and other Constellation Program stakeholders during the SRR to PDR timeframe. Other operations planning tools included Kaizen/Lean events, mockups and human factors analysis. The majority of products developed by this team are applicable as KSC prepares 21st Century Ground Systems for the Orion Multi-Purpose Crew Vehicle and Space Launch System.