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National Aeronautics and Space Administration

Michoud Assembly Facility Michoud Assembly Facility Concept of Operations Concept of Operations

(ConOps)(ConOps)

John BrunsonApril 21, 2008

NASA Internal Use Only

(Dec-13-07) Cloud-Chart 2

MAF Transition & Customer Interfaces

MAFMAF

TODAY A SINGLETODAY A SINGLE PROJECT FACILITYPROJECT FACILITY

TOMORROW A TOMORROW A MULTI-PROJECT FACILITYMULTI-PROJECT FACILITY

NCAMShuttle /

ET(thru 2010)

MAF’S MISSION IS CHANGING MAF’S MISSION IS CHANGING

Shuttle /ET

(thru 2010)

NCAM Orion/CEV

Ares VBoost

Ares 1UpperStage

Ares VEDS

NASACOTS

• Strategic & Operational Decisions returned to NASA Civil Service

• Operations cost shared• Multiple Prime Contractors• Independent Operation• Shared capabilities by multiple programs• Focus on multiple programs• Optimize plant space• Revenue stream created – Green Space Development/EUL• Collaborative partnership with State of Louisiana to expand NCAM

and support to programs

• Shuttle Program Managed• Totally Shuttle funded• Single Prime Contractor• Single program utilization• Minimum Government input to strategic

decisions• Dedicated capabilities and usage• Primary Focus: ET Production• Sub optimization of plant space• Green Space Undeveloped

Federal Tenants

Federal Tenants

Collaborative Partnershipsw/State of LA

Green Space Dev. (EUL)


MAF Management Approach

MAF Operations Past Present End State

Management Structure/Governance

• Program/Project– (MSFC/ET Project)

• Program/Project– (MSFC/ET Project)

• Single project program functionality reporting to Center Director

Multiple Management

• Single project program functionality reporting to Center Director

• Chartered MSFC organization with Control Board Authority

• Designated Center-Level AuthoritySingle Management

Budget/Funding Model • Funded by Single Project• Gov. Reimbursable

• Funded by Multiple Projects (3 WBS with fenced funding)

• Gov. reimbursable• Commercial reimbursable• State Commitment $20M

• Funded by Single BLI and Project Unique (IDIQ)• Gov reimbursable• Commercial reimbursable• State commitment $82M

Customer Interfaces • Single NASA Customer– ET

• Non-NASA Customers– USDA– Coast Guard– NCAM– Others

• Multiple NASA Customers– ET– Orion– Ares Upper Stage

• Non-NASA Customers– COTS– USDA– Coast Guard– NCAM– Others

• MAF Utilization Request Process• MAF Weekly Integrated Status Mtg.’s

• Multiple Projects– ET– Orion– Ares Upper Stage– Ares V

• Non-NASA Customers– COTS– USDA– Coast Guard– NCAM– LMSS-Commercial– Others

• MAF Level II and III Control Boards

Supplier Interfaces • ET - Prime • ET - Prime• Security• IT Support• NCAM

• MSFOC• Security• IT Support• A&E• NCAM

Operations • Contractor Managed• Single Mfg User• Services for Non-NASA Users• Steady State Facility

Utilization

• NASA/MSFC Managed• Multiple Mfg. Users• Services for Non-NASA Users• Serge & Gaps in Facility Utilization• ConOps Identified

• NASA/MSFC Managed• Multiple Mfg. Users• Services for Non-NASA Users• Serge & Gaps in Facility Utilization• Michoud Integrated Operations Plan


NASA ProgramPrime Contractors

Other MAFUsers

MSFOC

ConOps

MAF Concept of Operations Interfaces

4

MAF CS MSFOC

PrimeProject CS

Legend

SE&I

ETPSLE

Orion/NCAM

PSLE

Ares-IPSLE

Ares-VPSLE

ETProject

SE&I Support(CM, Scheduling,

Risk Mgt)

ET/LM

OrionProject

Orion/LMAres-IProject

Ares-IPSSM

Ares-1/Boeing

Ares-VProject

Ares-VPSSM

Ares-VContractor

NASA MAF I & O Office

MSFOC

Res. Office

Res. Office

Res. Office

Res. Office

UsersIntegration

ETPSSM

Orion/NCAMPSSM

MSFC/Michoud Organizational StructureMSFC/Michoud Organizational Structure(Proposed)(Proposed)

MSFC Center Director: D. King

Deputy Center Director: R. Lightfoot

Associate Center Director: R. Henderson

Instrument & Payload Systems Department

Propulsion SystemsDepartment

Mission OperationsLaboratory

Test Laboratory

Materials & ProcessesLaboratory

Engineering Directorate

Safety & MissionAssurance Directorate

Office of Human Capital

Office of Center Operations

Office ofDiversity &

Equal Opportunity

Office of Chief Counsel

Office of the Chief Information Officer

Office of the Chief Financial Officer

Office of Procurement

Spacecraft & Vehicle Systems Department

Office of Strategic Analysis & Comm.

Shuttle Propulsion Office

Science & Mission Systems Office

Exploration LaunchOffice

Michoud Facility


Governance

ESMDESMD SOMDSOMD

TRPCB

Shuttle CBConstellation CB

CxAMP

Michoud Facility CB

Michoud Facility CB

Headquarters-Level IHeadquarters-Level I

MSFC -Level IIMSFC -Level II

MAF-Level IIIMAF-Level III

Orion CB

Ares Projects CB NCAM CB

MAF Integ& Ops Office

CB

MAF Integ& Ops Office

CB

MSFCDir/Offices

ET CB

JICBJICB

MSFC Govern.SPC, CMC, IMSB

Integration & Operation issues will be resolved at the lowest possible level


Changing Supplier Interfaces/New Business Model

Project Management

Site Services

Logistics

Operations

Maintenance

Tenant Support

Schedule B - MOM

Production Support

C of F

Utilities

A&E Services

Schedule F – O&MSupport to Production

Facilities Contract

LMSS FACILITIES ORGANIZATION

NEW BUSINESS MODEL IMPACTS

MSFOC CONTRACT

Project Management

Site Services

Logistics

Operations

Maintenance

Tenant Support

C of F

Utilities

Facility Configuration Control

Scheduling of Shared Common Use Items

Integration Activities

Demand Services IDIQ Schedule

MFG Support

ADDITIONALSOURCING

Site ServicesIT (ODIN & UNITES) and Security (Coastal)

A&E Services

ET CONTRACT

Concept of Operations addresses these functional responsibilities that are created by the multi-program environment

Maintenance of Non Tooling Production

Equipment

Maintenance of Non Tooling Production

Equipment

Flight Hardware production for ET, Orion, & Ares Upper Stage are not impacted by the scope transition


MAF Integration & Operations Implementation(Proposed)

MAF Integration & Operations Office

Human Res.

LegalProcurementEngineering

PAO

CFO

Non-NASA Gov. User

NASA User Prime Cont.

Non-NASA Comm. User

NCAM

MAF On-site Personnel

NASA User ProgResident Offices

MSFOCMAF Mgr.

Contractor

Legend:

Integ & OpsSupportDept.

UserIntegration

Dept.

* On-Site Matrix Support to MM02

Coordination &Collaboration

Center Ops

* Center Operations

S&MA

* S&MA

On-Site Matrix Supportto MM02

*CIO

Manufacturing Support and Facility Operations Contractor (MSFOC)SAIC/ODIN Arch. & Eng. Coastal

MATRIXED AND CONTRACTOR SUPPORT ARE INTEGRAL TO ORGANIZATIONAL STRUCTURE

8NASA Internal Use Only


MAF Integration & Operations Office

Human Res.

LegalProc.

Engineering

PAO

CFO

(Applicable MMS42 / X new)

(Applicable MMS 38)

(Applicable MMS 41)

(Applicable MMS 19)

o General Support Facilities/Services -Facility Operation & Maint. Mgt. -Facility Projects Oversight CoF/A&E Planning & Implementation -Floor Plan Layout -Port/Harbor -Emergency Management Program -Office Space Coordination -Site Services -Taxi, -Trash,Vending, Cafeteria -Security -Health & Welfare Management -Medical Operation -Bloodborne Pathogens -Logistics -Shipping/Receiving -Transportation -Property Management/ Tracking -Environmental Management/ Remediation -Permitting, and Remediation -MMS Change Support

o Program Control (1FTE Program Analysis) -MSFOC Administration/Oversight-MAF Budget Development & Tracking-Cost Assessments-Reimbursable User Interface-Reporting-Contract Changes/IDIQ Evaluation/Coordination-PEB Administration

o User Support (1 FTE IS-IT, 1 FTE Security/ PAO,1FTE MMS/CM/DM) remaining areas)

-Governance/Control Board/Configuration Management/Data Management Support-User/Tenant Strategic Coordination-Information Technology Coordination/IT Planning-Risk Management Support-Security Liaison, Public Outreach -Export Control Plan-MMS Coordination (DCB Alt. Rep.) -ISO Certification Support

o PSSM’s “o Production Agreement Liaisono Integrated Operations Schedulingo Development & Track Requirements Plan, Scheduling, Maintenance, etc)o Engineering Coordinationo Operational Readiness Review Managemento Training/Certificationo MMS change Support

o Safety & Quality -Quality Control -Quality System Deficiency Notice -Audits -Industrial Safety -Occupational Safety Requirements -Hazard Identification -Mishaps -MMS Change Support

MAF Integration & Operations ImplementationOrganization Responsibilities & Personnel

Integ & OpsSupport

Dept.

UserIntegration

Dept.

* On-Site Matrix Supportto MM02

Center Ops

* Center Operations

S&MA

* S&MA

CIO

Eng.

New Functions

MAF Organization

Matrixed Support

NASA Internal Use Only

(Applicable MMS 14)(Applicable MMS 14) (Applicable MMS 9)(Applicable MMS 9)

(Total Applicable MMS 170+) (Total Applicable MMS 170+)


NASA ProgramPrime Contractors

Other MAFUsers

MSFOC

ConOps

MAF Concept of Operations Interfaces

10

MAF CS MSFOC

PrimeProject CS

Legend

SE&I

ETPSLE

Orion/NCAM

PSLE

Ares-IPSLE

Ares-VPSLE

ETProject


Risk Mgt)

ET/LM

OrionProject


Ares-IPSSM

Ares-1/Boeing

Ares-VProject

Ares-VPSSM

Ares-VContractor


MSFOC

Res. Office

Res. Office

Res. Office

Res. Office

UsersIntegration

ETPSSM

Orion/NCAMPSSM


ConOps Team Purpose and ApproachPurpose:• Develop a Concept Of Operations

– Focused on integration of production critical, shared capabilityproduction critical, shared capability– Driven by new integration production operations role

Advocate User Requirements Integrate Production Flow Manage Facility Resources

– Leveraged off existing systems• Identify

– Operations and integration architecture (tools, processes, roles, responsibilities), risk, and necessary trade studies for integrated operations

• Drive out a MAF operational philosophyApproach:• Implement the process in two phases:

– Transition (2007-2010)• MSFOC Transition (now until the end of CY 2008)• ET Fly-Out (2008-2010)

– Operational (2010 & Beyond)• Integrate MAF with the governance structures of MSFC and NASA and defines the

project & mission directorates as primary customers• Preserve, support, and enable the project & prime contractors roles & responsibilities,

and identify operational roles and responsibilities of civil service and contractors


ConOps Assumptions• Last production tank, ET 138 - used to evaluate schedule impacts – ET 139 impacts currently under evaluation

• Look at long-term operational approach: Focused on Integrated Production Operations

o Factor in NASA’s best interest (Minimizing Risk/Cost)o Shared service operational recommendations based on minimum impact and lowest costo End-States: Post October 2008; Post 2010

• External Tank production operational changes shall be avoided

• Priority use of the facility occurs in the following order (Highest to lowest): ET Projects, CxP elements, other NASA Projects, Other Non- NASA Government activities, Industry/Academia

• Facility O&M will be assumed by the new MSFOC


ConOps Focus Areas

• During the team’s study, issues related to transitioning production operations to a multi-User production facility, using a user-independent MSFOC were drawn out. They fell into four general focus areas:

Integrated Production Operations

General support facilities/services

Common production facilities/services

Dedicated production facilities/services

ConOps addressed key areas:• Policies/Procedures (LMSS, Institutional e.g. MMS, etc.)• Security (Perimeter to tenant space inside gate/walls)• Shipping/Receiving• Operation of Common Services (Cranes, lifts, tool cribs, machines shops)• Operation of Tenant specific equipment (NCAM, CEV fabrication equipment)


ConOpsIntegrated Production Operations

• Assumes in most cases each Production User has dedicated PSSM and PSLE support

• Also assumes MAF SE&I is matrixed support from MSFC “as needed”

SE&I

ETPSLE

Orion/NCAMPSLE

Ares-IPSLE

Ares-VPSLE

ETProject


Risk Mgt)

ET/LM

OrionProject


Ares-IPSSM

Ares-1/Boeing

Ares-VProject

Ares-VPSSM

Ares-VContractor


MSFOC

Res. Office

Res. Office

Res. Office

Res. Office

UsersIntegration

ETPSSM

Orion/NCAMPSSM

MAF CS

MSFOC

Prime

Project CS

Legend


ConOpsIntegrated Production Operations

Roles & Responsibilities:

• Project Offices will be responsible for providing requirements for common use production support, schedule inputs, support to the MAF Control Board, and CoF funding• Project Prime Contractors will be responsible for interfacing with the Project Office and the MAF Integration and Operations Office for implementation of project requirements, schedule data, and support to the MAF Control Board• MAF Integration and Operations Office will be responsible for overall MAF production integration• Production Support Systems Manager (PSSM’s) is a NASA Civil Servant function and responsibilities include coordination with MAF Users and other MAF personnel to achieve requirements development, management, and implementation• Production Support Lead Engineer (PSLE’s) is a MSFOC Contractor function

and responsibilities include assisting the PSSM in coordination with MAF Users and other MAF personnel to achieve requirements development, management, and implementation


ConOps General Support Facilities/Services

Production & Environmental Systems•Environmental Compliance Program•Environmental Remediation Program•Sanitary Sewerage System •Chemical Waste System •Industrial Wastewater Treatment Facility •Plant Air system•Chilled Water System•Process Water system•GN2 System•De-mineralized Water System •Foreign Object Debris Control Program

Utility Systems•Fuel Oil Transfer System •Steam Distribution System •Natural Gas System •Potable Water System•Storm Drainage System

Industrial Safety•Pump Stations and Houses•Fire Water System•Occupational Health

Maintenance, certification, and operations of all building/facility infrastructure/equip/systems including production support systems:

• MAF General Support Facilities/Services • Roads and Grounds• Operations and Maintenance• Shipping/Receiving/Transportation • Security - Perimeter and Personal Security• IT/Comm. – IT Backbone, Network

Access• Emergency Preparedness Management• Quality• Personnel Training/Certification Program • Equipment/System Certification• Custodial Services


ConOps Common Production Facilities/Services

Multiple Users are required to share common “production” facilities, services, andequipment. “While in use by ET/LM, they will continue to have priority access andprovide for operations (Operators, Safety Quality, Policy, and Procedures) whilethey process ET hardware”

LabsChemical Clean facility (component cleaning, and precision cleaning)Component Painting Machine ShopVertical Assembly BuildingBuildings 114, 131, 113, 175, and 190NCAMSystems Engineering Buildings (131 and 318)Building 303LH2 Pneumatic Test Facility

MAF ConOps Spreadsheet tool identifies MAF Facilities/Capabilities (200+ line items) reflect agreements for Manage, Operate, and Maintain in three time frames


-Steam Distribution System-Natural Gas System-Plant Air system-De-mineralized Water System

-Chemical Waste System-Industrial Wastewater Treatment System

Production SupportSystems

Specific to Cell

General Support Systems

ProductionSupportInstrumentation,Mechanical,Fluids/Gases…

ProjectSpecificTooling,Instrumentation

Project Hardware

Production Common Use Cell-E

Gen Support Fac/SvcsSchedule B

Common Production Fac/SvcsSchedule A/F

The Defining Interface

Current LMSS Schedule A/F & B Project (Production H/W)

ConOpsCommon Production Support Interfaces


ConOpsDedicated Production Facilities/Services

• Dedicated Production Facilities and Services are reserved and set aside to house and support production operations of a single user

o These areas are to be contiguous, if possibleo Capable of supporting efficient internal processeso Support separation and security between userso Have adequate access to shared areas

• Projects supported by prime contractors are responsible for managing, operating, and maintaining their equipment, tooling and other operations that occur within their dedicated area(s)

• MSFOC will provideo Standard facilities services and maintenance serviceso Construction and alteration services consistent with approved CoF programs


MAF Multi-Program Production OperationsIntegration Approach

Laying out the Facilities/functions and ask the question Who “Manages, Operates, Maintains” by Date

• 200+ Line Items identifying the MAF Facilities/Functions

ETManage Operate Maintain

MSFOCManage Operate Maintain

Ares IManage Operate Maintain

- Bld 103- Machine Shop-Clean Line- …

During ET

Manage Operation Maintain Manage Operate Maintain Manage Operate Maintain Manage Operate Maintain Manage Operate Maintain Manage Operate Maintain Manage Operate Manage Operate

Multi Tenant Production and Non-Production Integration x x x x x x

Integrated Facilities Instututional Systems Safety x x xLogistics

Shipping/Receiving

x- Responsible for Spec material Inspection/move




Transportation

x- Responsible for flt hadrware moves x

x- Responsible for material moves for critical hardware

x- Responsible for material moves in a supporting role but not touching critical hardware

Environmental (NEPA) x

x- Responsible for environmental control for production

Information Technologyx- Begins post award

x- Begins post award

Contract through MSFC IT

x- Responsible for controlling for production hardware

x- Responsible for controlling and supporting production hardware scheduling and work flow

Security x- Begins post award


x-responsible for inputing requirements to the facilities

x- Responsible for controlling and supporting production hardware scheduling and work flow at gates and in the electronic data transfer

Sanitary Sewerage Systemx- Begins post award



x- Responsible for controlling and supporting production hardware areas and non-production hardware areas

Chemical Waste Systemx- Begins post award




Industrial Wastewater Treatment Facility





Fuel Oil Transfer Systemx- Begins post award




Electrical Distribution System x- Begins post award




Steam Distribution Systemx- Begins post award




Natural Gas Systemx- Begins post award




Facility/Capability

Transferred to MSFC MSFOC

ET/LM

Post ET Production (only identy delta changes once ET is terminated, I.e. something

MSFC - MSFOC

MSFC -Other than MSFOC (I.e., NASA-MAF MIOSM, MSFC ED/S&MA/Facilities/EO…

oversight…) NCAM Upper Stage Orion Small/ Industry Tenant MSFC - MSFOC


MAF Integrated Production Operations Summary

General Support Facility/Services Common Production Facility/Services Dedicated Prod. Facilities/Services

MAF Facility Integration

Manage, Operate, Maintain Manage, Operate, Maintain Manage, Operate, Maintain

Approach to solving issues using the 200+ Line Item ConOps Spreadsheet

• Advocate User Requirements• Integrate Production resource Schedules/Flow

• Manage Facility Resources• Identify and resolve utilization conflicts• Retain critical production/facility skills


Facility Critical Process Area & Operations

Who Manages/Operates/Maintains Cells A-F, Mix Room, Buildings 130, 131, 318?

Managex - manage cell for

flt h/w until ET last use

Operatex - operate cell for flt h/w until last use

Maintain x - maintain production critical systems. This includes critical

system control mechanics items.

Managex - manage cell for multi-program environment. Includes scheduling and configuration control. Prior toturnover, - MSFOC will coordinate with ET to obtain engineering design, procedures and any updates for the cell.MSFOC will integrate future users requirements (software and hardware) to ensure cell will accommodate new users when ET is complete. - MSFOC will implement modifications to cell when ET is finished. MSFOC will coordinate integrated usage of cell after ET is complete. New users will be accommodated on non-interference basis (not affecting ET's CP) to enable planning/design. MSFOC will ensure critical skills are maintained during transition from ET to multi-user environment

Maintainx - Begins post award. This includes skilled craft mechanics

OperateN/A - for ET

Post ET MSFOCProvides

Operators as an optional Service –

IDIQ

Facilities Spreadsheet Data

Most of this transfers to MSFOCaround the Late 2009 - Mid 2010timeframe. Minimal schedule impactsWith ET-138, impacts increase with ET139+(Con Ops team trying to obtain 139+ scheduleto evaluate overall impacts)

Transition to MSFOC

ET/LM MSFOC


Facility Joint use areas - LaboratoriesWho Manages/Operates/Maintains Chemistry, Metallurgical, Structural Test, TPS, Weld?

ET/LM MSFOC

Managex - manage ET

related day -to - day by

ET/LM

Operatex - provide operators

and analyst until ET last use

Maintain N/A

Managex - begins post award (overall

management…with ET non-interference)

Maintainx - Begins post

award. (12/1/08)

Operatex - provide Operators

and Analyst for future

Users, IDIQ

Facilities Spreadsheet Data

Transition to MSFOC

12/1/2008 to MSFOC. The users can provide personnel to operate the equipment.

• 85-95% of work is ET specific, 5-15% MAF infrastructure • Labs: Chemistry, Metallurgical, Structural Test, TPS, Weld • Some work generic – (e.g. some receiving inspection activities, IWTF/clean line

solution analysis)• Much work is high priority, process specific (F/A, mat’l “fingerprinting”, TPS NDE, ET

weld schedules)• LM engineer/tech discipline experts; highly experienced in ET legacy matl/process

knowledge• Discrepant ET hardware analysis/flight rationale by MSFOC labs, ET Project/LM

retain liability


Facility Joint Use Equipment - Transportation & Handling

Who Manages/Operates/Maintains Joint Use?

ET/LM MSFOC Manage

x - manage cranes For flt h/w until

ET last use

Operatex - operate cranes

for ET flt h/w .

Maintain N/A

Managex - Each remaining crane shall revert to MSFOC managementat last ET use. Common use

cranes shall be managed by MSFOC. Management of dedicated user cranes

shall be transferred to the user.

Maintainx - Begins

post award.

Operatex - Operates

cranes in shared areas and at

user's request an

operator will be provided

for non-flt H/W or flt H/W moves in other areas,

IDIQ

Facilities Spreadsheet Data 12/1/2008 maintenance

Transition to MSFOC

• MSFOC has overall crane mgmt/maintenance not an issue• General moves, small component moves the responsibility of contractor not an

issue• Crane crew rapid response, off-shift coverage, “critical systems” support

commitment are concerns • High value/high schedule risk hdwr moves (straddle carriers, Cell A cranes,

transporters) are major concern• Move crews require extensive training and experience, detailed process/tooling

knowledge• ET deliveries/Shuttle manifest absolutely intolerant of major mishap


ConOps Summary

The proposed Concept of Operations:o Facilitates getting hardware out the dooro Minimizes risk to production programs o Provides a flexible approach to the integration of multiple production programs “under one roof”o Maximizes the use of NASA resourceso Meets the strategic MAF goals for a Multi-program production environmento Provides a process for advocating user requirementso Provides for governance of production operations (facility O&M, dedicated production areas, and shared areas and services) involving all the key Users

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