Preface. P.1 Purpose. P.3 Authority. P.4 References. Procedures for Performing a Failure Modes, Effects, and Criticality

Pfa Sandad fo Pfomng a Falu Mod and Effs Analyss (FMEA) and Esablshng a Cal Ims Ls (CIL) (DRAFT) Flgh Assuan Podu (FAP) 322-209 P.1 Pupos An FMEA an b dsbd as a sysma goup of avs nndd o: (a) ognz and valua h ponal falu(s) of an m o poss and h ffs of ha falu, (b) dnfy aons ha ould lmna o du h lklhood of h ponal falu oung (pobably of oun) () doumn h poss. Ths Sandad dfns h who, wha, why, whn, and how lad o h pfoman of a Falu Mods and Effs Analyss (FMEA) and sablshng a Cal Ims Ls (CIL). Why an FMEA pfomd h undlyng nn of pfomng an FMEA Whn an FMEA pfomd Whn n h Pogam Cyl FMEAs a pfomd. FMEAs pfomd dung h plmnay and dald dsgn phass of a pogam hav as a pupos h aon of h dsgn o mov al and hgh poy falu mods. FMEA aons pfomd la a usd o valda h dsgn has no al o hgh poy falu mods manng af ov aon has bn mplmnd. Who pfoms h FMEA whh psonnl a nvolvd n pfomng ah yp of FMEA Wha s onand n an FMEA h xpd nfomaon ha s npu and oupu dung h pfoman of an FMEA How h FMEA s pfomd h aual sp by sp appoah o pfomng an FMEA Th Cal Ims Ls olls nfomaon dvlopd by h FMEA dnfyng spf sysms, sub-sysms, funons, omponns, p pas, and/o posss ha f fald psn sk o human lf o lmb, msson suss, o dsuon of spaaf. P.2 Applably Ths sandad s applabl o all Mssons, Spaaf, Insumns, Gound Sysms, sysms, sub-sysms, sofwa and omponns dvlopd by, onad by, o manufaud by NASA Goddad Spa Flgh Cn (GSFC) and/o any subsday faly. Pogams nad ousd of GSFC ha hav qud FMEA podus ha m o xd h qumns onand hn shall ak pdn ov hs sandad. Conad fals and oh NASA ss o Pan ss ha us FMEA podus ha m o xd h qumns of hs sandad may us hos podus, povdd a opy of ha podu s submd whh ah FMEA ppad. P.3 Auhoy P.4 Rfns GPR 7120.4A MIL-STD-1629 Rsk Managmn Podus fo Pfomng a Falu Mods, Effs, and Caly 1

SAE J1739 P-302-720 Analyss Ponal Falu Mod and Effs Analyss n Dsgn (Dsgn FMEA), Ponal Falu Mod and Effs Analyss n Manufaung and Assmbly Posss (Poss FMEA), and Ponal Falu Mod and Effs Analyss fo Mahny (Mahny FMEA) Pfomng a Falu Mod and Effs Analyss P.5 Canllaon Flgh Assuan Podu P-302-720 PERFORMING A FAILURE MODE AND EFFECTS ANALYSIS P.6 Safy Falu mods dnfd as affng Safy shall b pod o h ognzan Poj Safy Manag fo nluson n h appopa safy analyss. P.7 Tanng Tanng n Falu Mod and Effs Analyss shall b mad avalabl o all psonnl papang n h FMEA poss. P.8 Rods P.9 Ms P.10 Dfnons 1. Im und dvlopmn a msson, spaaf, nsumn, sysm, subsysm, sofwa, o omponn ha s undgong dvlopmn a NASA Goddad Spa Flgh Cn o a a onao faly. 2. Funonal Blok Dagam - A dagam ha shows by ons vsual shohand h vaous npus and oupus qud o pfom a funon. 3. Infa - Th pon o aa wh a laonshp xss bwn wo o mo pas, sysms, pogams, psons, o podus whn physal and/o funonal ompably s qud. 4. Falu Mod and Effs Analyss (FMEA) - A podu by whh ah dbl falu mod of ah m fom a low ndnu lvl o h hghs s analyzd o dmn h ffs on h sysm and o lassfy ah ponal falu mod n aodan wh h svy of s ff. FMEA ypally assums ha h m und analyss was poply manufaud, and was wokng mmdaly bfo falu. Du o h spal nau of spaaf, launh vhls, and oh NASA hadwa, hs assumpon dos no hold u. Th mpa of fauls du o h assmbly of spaaf o launh vhls af I&T; h ffs of shok and vbaon du o launh, njon no ob, powd us, dploymn of sola panls, nsumns, ovs,. mus b addssd n h FMEA. 5. Falu Mod - A paula way n whh an m fals, o pfom s nndd funon suh as fau of a suual mmb bang a load o sho u n a pow amplf. Th falu mod s nomally obsvd by nspon of h m o funonal sng. Dspon of falu mod dpnds upon h ndnu lvl and m funon.. 6. Falu Mhansm Th aual physal poss ladng o a falu mod.. (.. 2

shod apao du o ovsss volag sug,) sofwa falu du o nably o handl npu valus, poss falu du o msnpaon of ambguous nsuon,.).). 7. Falu Eff h mpa a paula Falu Mod has a h Loal Lvl (Componn o Sub-Assmbly), Nx Hgh Lvl (sub-sysm o Sysm), and Msson Lvl. 8. Oun - A numal valu assgnd o h lklhood ha a falu mod, du o a an aus, wll ou. 9. Svy - A numal valu assssng h sousnss of h ponal falu ff. 10. Mgaon A numal valu assgnd o h ably of a dsgn o mga h ponal falu ff. 11. Don - A numal valu assgnd o h ably of a poss o pvn, d, o mnmz h mpa of a ponal falu. 12. Rsk Poy Numb (RPN) - Th podu of Oun, Svy, and Mgaon o Don valus. Usd o poz sks fom ponal falu mods. 13. Falu Mod Donay a doumn ha dnfs falu mods fo sandad funonal o hadwa ms (.. Sho o Opn fo a Dod) 14. Indnu Lvls - Th hahy of hadwa lvls fom h pa o h omponn o h subsysm o h sysm,. 15. Rdundany - Mo han on ndpndn mans of pfomng a funon. Th a dffn knds of dundany, nludng: a. Opaonal - Rdundan ms, all of whh a ngzd dung h opang yl; nluds load-shang, whn dundan ms a onnd n a mann suh ha upon falu of on m, h oh wll onnu o pfom h funon. I s no nssay o swh ou h fald m o swh n h dundan on. b. Cold Sandby - Ims ha a nopav (hav no pow appld) unl hy a swhd n upon falu of h pmay m.. Lk Rdundany - Idnal ms pfomng h sam funon. d. Unlk Rdundany - Nondnal ms pfomng h sam funon.. Funonal Rdundany/Opaonal Wokaounds 16. Poss Ingy - Rlad o poss pfoman whn spfaon wh nomal ovsgh and supvson, and whou h nd fo spal managmn nvnon. 17. Poss usom. A NASA GSFC dpamn, onao, sub- onao, poj o pogam ha vs oupus fom h poss und analyss. 18. Poss own. A NASA GSFC dpamn, onao, sub- onao, poj o pogam ha has onol ov h poss und analyss. 19. Poss suppl. A NASA GSFC dpamn, onao, sub- onao, poj o pogam ha povds npus o h poss und analyss. 20. Cal Ims Ls - Chap 1 Funonal FMEA 1.1 Rqumns A Funonal FMEA s pfomd as soon as suffn nfomaon s avalabl o onsu a funonal blok dagam of h m und dvlopmn. In od o pfom a Funonal FMEA, h followng nfomaon, as a mnmum, s qud. 3

a) A funonal blok dagam of h m und dvlopmn bokn down o h subsysm and omponn lvl. b) A dspon of ah funon dpd n h funonal blok dagam nludng qud npus and oupus fo ah blok. ) Th mann n whh ah of h qud oupus an fal (.. low oupu, wong fquny, no moon,.). d) Th mpa o ff of loss of ah funonal oupu dpd n h funonal blok dagam on h nsumn, spaaf, and/o msson. (h mpas o ffs may b dvlopd usng a am appoah o pfomng h Funonal FMEA) ) Th ompnsang povsons dsgnd no h m o mga h ffs of a funonal oupu falu (.. dundany, alna opang mods,.). Th Funonal FMEA s manand as a lvng doumn houghou h lf of a Poj/Pogam. Fo xampl, whn hangs a mad o h funonal blok dagam, h Funonal FMEA shall b updad o addss hs hangs. 1.2 Applably A Funonal FMEA s pfomd fo Msson, Spaaf, Insumn, Gound Sysm, sysms, sub-sysms, sofwa and omponn dung Phas A of h dvlopmn poss. 1.3 Mhodology Th Funonal FMEA should whnv possbl b pfomd by an FMEA Tam onssng of a Rlably Engn, Sysms Engn, Elal Engn, Mhanal Engn, I&T Engn, and Msson Opaons Engn. Th FMEA Poss assums ha all npus o h Im, Sysm, o Msson und analyss a whn spfaon and falu mods ou on a a m. (.. whn valuang a ommunaons sysm on a spaaf, h sgnals fom h Eah saon a assumd o b whn spfd lms a all ms) 1.3.1. Poss Flow. Th poss flow fo h Funonal FMEA s shown n Fgu 1-1. 1.3.2. Funonal FMEA Had. Th had nfomaon on h Funonal FMEA fom (s Fgu 1-2) shall b ompld fo ah m analyzd. Th op lvl Msson, Insumn, Sysm,. nam shall b nd n h had. All Tam mmb nams and funons shall b doumnd. 1.3.3 Subsysm/omponn Nam.. Eah m und dvlopmn shall b domposd no s onsun subsysms omponns o pas. Th subsysm and omponn o pa nams shall b nd n olumn 1 of h Funonal FMEA fom. 4

1.3.3.1. Subsysms. Eah subsysm shall b dnfd on h Funonal Blok Dagam. 1.3.3.2. Componns. Componns shall b dnfd on h Funonal Blok Dagam. 1.3.4. Subsysm/Componn Funon and Pfoman Rqumns. Th funon(s) of ah subsysm and s pfoman qumns (.., Fquny, oupu pow, Fld of Vw,.) shall b nd n olumn 1 of h Funonal FMEA fom af h subsysm/omponn nam. 1.3.5. Ponal Falu Mods. Fo ah Subsysm/Componn Funon, all Ponal Falu Mods shall b posulad. Th Ponal Falu Mods shall b squnally numbd and nd n olumn 2 of h Funonal FMEA fom. If povdd, a Falu Mod Donay should b usd o dnfy h ponal falu mods. If nw falu mods a dnfd, h Falu Mod Donay shall b updad. Fo ah Ponal Falu Mod, olumns 2 (Ponal Falu Mod), 3 (Ponal Caus(s) of Falu), 4, (Oun) 5 (Ponal Eff(s) of Falu), 6 (Svy), 7 (Svy Cagoy), 8 (Funonal/ Dsgn Conol), and 9 (Mgaon) shall b ompld. Compu basd foms should b usd o od FMEA daa. 1.3.5.1. Puhasd subsysms/omponns. Fo puhasd subsysms/ omponns, h suppl, wh possbl, shall supply h Ponal Falu Mods and Effs Analyss. 1.3.5.2. GSFC Dsgnd subsysms/omponns. Fo GSFC Dsgnd subsysms/omponns, h Ponal Falu Mods shall b dnfd by h FMEA am. If Ponal Falu Mods a bng dmnd by bansomng o am valuaon, a blakboad o ompu pojo dsplay should b usd o od h Ponal Falu Mods unl h Funonal FMEA fom an b poply flld ou. 1.3.6. Ponal Falu Causs. Ponal Falu Causs a h aual falu mhansms avad by loads appld o h sysm, sub sysm, omponn o pa fo h falu mod obsvd and an b a hadwa, sofwa, o opang podu falu. Whn pfomng a Funonal FMEA, s possbl o hav mulpl Ponal Falu Causs fo a Ponal Falu Mod. Ponal Falu Causs wh a unqu l dsgnaon fo ah falu mod shall b nd n Column 3 of h Funonal FMEA fom. 1.3.7 Oun. Oun s h lav fquny o lklhood of oun of h Ponal Falu Caus. Tabl 3-1 onans h song fo Oun. Th Oun valu shall b nd n olumn 4 of h Funonal FMEA fom. 1.3.8. Ponal Eff(s) of Falu. Ponal Falu Effs a h mpa of h Ponal Falu Mod on h sub-sysm/omponn (Loal Eff); h sysm (fo sub-sysm) o sub-sysm (fo omponn) (Nx Hgh Lvl Eff); and Msson o End Im (Msson Lvl Eff). Pson(s) opang o sng h omponns, subsysms, sysms, End Im, o Msson may b mpad by h Falu Eff as wll. Fo ah Ponal Falu Mod, on o mo Ponal Effs of Falu (.. duon of sn daa, loss of msson, safy,.) a h Loal, Nx Hgh, and Msson Lvls shall b nd n olumn 5 of h Funonal FMEA fom. 5

I s possbl ha h Ponal Falu Eff s only a h Loal o Loal and Nx Hgh Lvl. If ha s h as, Non should b nd as h ff a h Msson Lvl and/o Nx Hgh Lvl. 1.3.9. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 3-2. Ths valus shall b nd n olumn 6 of h Funonal FMEA fom. 1.3.10. Mgang Faos. Fo ah Ponal Caus of Falu, h Mgang Faos (Funons/Dsgns n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and nd n olumn 7 of h Funonal FMEA fom. 1.3.11. Mgaon. Eah Mgang Fao shall b assgnd a Mgaon ankng basd on h valus dald n Tabl 3-3. Ths valus shall b nd n olumn 8 of h Funonal FMEA fom. 1.3.12. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Mgaon/Don ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. Th RPN s nd n olumn 9 of h Funonal FMEA fom. 1.3.13. Svy Cagoy. Th Svy Cagoy shall b nd n olumn 10 of h Funonal FMEA fom. Th a fo Svy Cagoy a onand n Tabl 1-4. 1.3.14 Cal Ims Ls. All sub-sysms/omponns wh Ponal Falu Mods wh Svy Cagoy 1, 1R, 1S, o 2 shall b plad on h Cal Ims Ls (s Chap 9). 1.4 Cov Aon 1.4.1. Mandaoy Cov Aon. All ponal falu mods n Svy Cagos 1, 1R and 2 a Cal and qu ov aon o du h Svy Cagoy o 2R, 3 o 4. Ponal Falu mods lassfd as 1, 1R, o 2 shall hav Dsgn FMEAs pfomd o asan h ffvnss of h Cov Aon akn. Ponal falu mods lassfd as Svy Cagoy 2R shall hav a Dsgn FMEA pfomd o asan h nd fo Cov Aon. 1.4.2 Rommndd Aon Analyss (Dson Mas). Fgus 1-3 and 1-4 a Dson Mas fo dmnng whn a Rommndd Cov Aon s qud. Ths mas a fo ponal falu mods no n Svy Cagos 1, 1R, and 2. 1.4.2.1. Hgh Poy Cov Aon. Ponal falu mods ha ou n Quadan C of h max, and quadan B o D of h oh max, a hgh poy anddas fo pvnv aon. Dsons o df aon mus b doumnd n olumn 11 and appovd by Poj/Pogam Managmn. Shdul and budg may b faos o df aon. 1.4.2.2. Mdum Poy Cov Aon. Ponal falu mods ha ou n Quadans B 6

o D of boh mas, a mdum poy anddas fo pvnv aon. Shdul and budg may b faos o df aon. 1.4.2.3. Low Poy Cov Aon. All oh ponal falu mods a low poy anddas fo pvnv aon. Wh shdul and budg pm, pvnv aons may b dvlopd and mplmnd. 1.4.3. Rommndd Aons a lad o Dsgn, Tsng, and Mgaon. Rommndd aons o b akn as a sul of h Rommndd Aon Analyss (paa. 1.4.2) shall b nd n olumn 11 of h Funonal FMEA fom. Th nn of hs aons s o du h valus of on o mo of h Oun, Svy, and Mgaon ankngs, and hus du h valu of h RPN as wll as mov h m no a low poy quadan. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Mandaoy Cov aons shall no b pmd. No Aon Rqud fo a Hgh Poy falu shall qu Pogam Managmn and CSO appoval n wng. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/Dpamn(s). 1.4.4. Dpamn and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h Funonal FMEA fom. 1.4.4. Dsbuon of FMEA. Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav Aon Ims o ompl. 1.4.5. Aons Takn 1.4.5.1. Th Aons Takn and h modfd Svy, Oun, and Mgaon ankngs shall b nd n olumns 12 hu 15 of h Funonal FMEA fom. 1.4.5.2. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas duon n RPN. 1.4.5.3. To dmn h duon n RPN, h RPN s alulad as f ah ommndd aon s mplmnd. 1.4.5.4. Th Rommndd aons a lassfd as Mandaoy, Hgh Poy, Mdum Poy, o Low Poy. Th Rommndd aons a hn addssd whn ah agoy n od of RPN valu. Whn a Rommndd Aon s no mplmnd, ha aon shall b jusfd and appovd n wng by Pogam Managmn and h CSO. 1.4.5.5. Nw RPN. A nw RPN shall b alulad and nd n olumn 17 of h Infa FMEA fom fo vy aon akn. Commn [MVS1]: Funonal o nfa? 7

Tabl 1-1 - Oun Rankng Ca Lklhood of Oun Exmly Hgh Vy Hgh Hgh Modaly Hgh Moda Modaly Low Low Vy Low Exmly Low Rmo Ca: Possbl Falu Ras/Pobably of Falu Falu a of lss han 5 FPMH/Pobably of Falu Dung Msson <0.2 Falu a of lss han 2 FPMH/Pobably of Falu Dung Msson <0.1 Falu a of lss han 1 FPMH/Pobably of Falu Dung Msson <0.05 Falu a of lss han 200 FIT/Pobably of Falu Dung Msson <0.01 Falu a of lss han 100 FIT/Pobably of Falu Dung Msson <0.005 Falu a of lss han 20 FIT/Pobably of Falu Dung Msson <0.001 Falu a of lss han 10 FIT/Pobably of Falu Dung Msson <0.0005 Falu a of lss han 2 FIT/Pobably of Falu Dung Msson <0.0001 Falu a of lss han 1 FIT/Pobably of Falu Dung Msson <0.00005 Falu a of lss han 0.2 FIT/Pobably of Falu Dung Msson <0.00001 Rang 10 9 8 7 6 5 4 3 2 1 Commn [MVS2]: < o >? 8

Tabl 1-2 - Svy Rankng Ca Svy = (Msson Impa + Los Msson Tm) * Safy/Msson Loss Msson Impa (1-5) Eff Ca: Svy of Eff Rang Vy Sous Msson Capably >75% loss of Msson Capably 5 Eff Sous Msson Capably Eff >50% loss of Msson Capably 4 Moda Msson Capably >25% loss of Msson Capably 3 Eff Mno Msson Capably Eff >10% loss of Msson Capably 2 No Msson Capably Eff No mpa on Msson Capably 1 Los Msson Tm (1-5) Vy Hgh Los Msson m Ga han 30 days los msson m 5 Hgh Los Msson m Ga han 15 days los msson m 4 Moda Los Msson m Ga han 7 days los msson m 3 Low Los Msson m Ga han 1 days los msson m 2 No Los Msson m No Los Msson Tm 1 Safy o Msson Loss (1-10) Sgnfan Safy Hazad o Toal Immda lf o lmb hanng hazad o 10 Loss of Msson Mno Safy Hazad, Majo Spaaf Damag o Majo Loss of Msson Capabls Sgnfan Spaaf Damag o Loss oal loss of msson Mno Injuy Hazad (no ha o lf o lmb) Majo (50<75%) Sgnfan (25<50%) Spaaf damag o Msson Loss 5 3 No Hazads o Loss of Msson No safy ssu o sgnfan mahny damag. 1 9

Mgaon Ca Non Vy Rmo Rmo Vy Low Low Moda Modaly Hgh Hgh Vy Hgh Almos Can Tabl 1-3 - Mgaon Rankng Ca Lklhood of Mgaon by Dsgn o Conols Th s no Mgaon of h Falu Mod o s subsqun Falu Eff Th s a vy mo pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (lss han 10% pobably fo mgaon) Th s a mo pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (10 > 20% pobably fo mgaon) Th s a vy low han h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (20 > 30% pobably fo mgaon) Th s a Low pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (30 > 40% pobably fo mgaon) Th s a Moda pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (40 > 60% pobably fo mgaon) Th s a Modaly Hgh pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (60 > 80% pobably fo mgaon) Th s a Hgh pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (80 > 90% pobably fo mgaon) Th s a Vy Hgh pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (90 > 99% pobably fo mgaon) Th s an almos an pobably h Dsgn wll mga h Falu Mod o s subsqun Falu Eff (> 99% pobably fo mgaon) Rang 10 9 8 7 6 5 4 3 2 1 10

Tabl 1-4 Svy Cagoy Cagoy Dsgnaon Dspon 1 Caasoph Falu mods ha ould sul n sous njuy o loss of lf, o damag o h launh vhl. 1R Caasoph Falu mods of dnal o quvaln dundan hadwa ms ha, f all fald, ould sul n Cagoy 1 ffs. 2 Cal Falu mods ha ould sul n loss of on o mo msson objvs as dfnd by h GSFC poj off. 2R Cal Falu mods of dnal o quvaln dundan hadwa ms ha ould sul n Cagoy 2 ffs f all fald. 3 Sgnfan Falu mods ha ould aus dgadaon o msson objvs. 4 Mno Falu mods ha ould sul n nsgnfan o no loss o msson objvs. Cagoy Svy Dfnon Add nw Svy Cagos (2A and 2B) o dsngush bwn falu mods ha ould sul n oal loss of msson and loss of on o mo msson objvs (whou a oal loss of h msson)? 1 1R 1S Caasoph Falu mods ha ould sul n sous njuy, loss of lf (flgh o gound psonnl), o loss of launh vhl. Falu mods of dnal o quvaln dundan hadwa ms ha, f all fald, ould sul n agoy 1 ffs. Falu n a safy o hazad monong sysm ha ould aus h sysm o fal o d a hazadous ondon o fal o opa dung suh ondon and lad o Svy Cagoy 1 onsquns. 2A 2B 2R 3 4 Cal Falu mods ha ould sul n loss of all mnmum msson objvs as dfnd by h GSFC Poj Off. Cal Falu mods ha ould sul n loss of on o mo mnmum msson objvs as dfnd by h GSFC Poj Off, whou a loss of all of hm. Falu mods of dnal o quvaln dundan hadwa ms ha ould sul n Cagoy 2 ffs f all fald. Sgnfan Falu mods ha ould aus dgadaon o msson objvs. Mno Falu mods ha ould sul n nsgnfan o no loss o msson objvs 11

Rvson o Funonal Blok Dagam Nw Funonal Blok Dagam Ronvn FMEA Tam Oganz FMEA Tam Rvs Funonal FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh Funonal FMEA and CIL Pfom Funonal FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda Funonal FMEA Fgu 1-1 Funonal FMEA Poss Flow 12

Msson: Sysm: Subsysm/ Componn Nam Ponal Falu Mods Sysms Engn: CSO: Ponal Causs of Falu O u n Funonal Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Mgang Faos M g a o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y M g a o n R P N Fgu 1-2 Funonal FMEA Fom 13

10 Quadan B Quadan C Oun 6 5 Quadan A Quadan D 1 1 5 6 10 10 Svy Fgu 1-3 Svy Oun Dson Max Quadan B Quadan C Mgaon 6 5 Quadan A Quadan D 1 1 5 6 10 Svy Fgu 1-4 Svy Mgaon Dson Max 14

Chap 2 Dsgn FMEA 2.1 Rqumns A Funonal FMEA should hav bn pfomd bfo h sub-sysm/omponn s submd o a Dsgn FMEA. A Dsgn FMEA shall b pfomd whn suffn dal dsgn nfomaon s avalabl o dnfy all h onsun p pas of h dsgn m. In od o pfom a Dsgn FMEA, h followng nfomaon, as a mnmum, s qud. a) A funonal blok dagam of h m und dvlopmn bokn down o h subsysm and omponn lvl. b) A dspon of ah funon dpd n h funonal blok dagam nludng qud npus and oupus fo ah blok. ) Shmas (lal, mhanal [nludng hmal, flud, mhansm]) and pnpls of opaon fo h dsgn und analyss. d) Th mann n whh ah of h oupus an fal (.. low oupu, wong fquny, no moon,.). ) Th mpa o ff of loss of ah funonal oupu dpd n h funonal blok dagam on h nsumn, spaaf, and/o msson. f) Th ompnsang povsons dsgnd no h m o mga h ffs of a funonal oupu falu (.. dundany, alna opang mods,.). Th Dsgn FMEA shall b manand as a lvng doumn houghou h lf of a Poj/Pogam. Tha s, whn hangs a mad o h dald dsgn, h Dsgn FMEA shall b updad o addss hs hangs. 2.2 Applably A Dsgn FMEAs o h onsun p pa lvl shall b pfomd fo Class A mssons, and all sub-sysms/omponns havng falu mods n Svy Cagos 1, 1R, 2 and 2R. A Dsgn FMEA s usually pfomd dung Phas B of h dvlopmn poss. 2.3 Mhodology If a Funonal FMEA has bn pfomd, h Dsgn FMEA may b pfomd by an FMEA analys, usually a Rlably Engn. If a Funonal FMEA has no bn pfomd, s hghly ommndd ha poons of h FMEA lad o Nx Hgh Lvl and Msson Effs b pfomd wh a Tam nludng Sysm Engnng, Msson Opaons, and Dsgn Engnng. Th FMEA Poss assums ha all npus o h Im, Sysm, Msson und analyss 15

a whn spfaon and falu mods ou on a a m. (.. whn valuang a ommunaons sysm on a spaaf, h sgnals fom h Eah saon a assumd o b whn spfd lms a all ms) 2.3.1. Poss Flow. Th poss flow fo h Dsgn FMEA s shown n Fgu 2-1. 2.3.2. Dsgn FMEA Had. Th had nfomaon on h Dsgn FMEA fom (s Fgu 2-2) shall b ompld fo ah Dsgn analyzd. Th op lvl Msson, Insumn, Sysm,. nam shall b nd n h had as wll as h Dsgn bng analyzd. If a am s usd fo pas of h analyss, all Tam mmb nams and funons shall b doumnd. 2.3.3 P Pa Nam. Eah dsgn shall b bokn down no s onsun p pas. Th p pa nams shall b nd n olumn 1 of h Dsgn FMEA fom. 2.3.5. Ponal Falu Mods. Fo ah p pa, all Ponal Falu Mods shall b dnfd. Th Ponal Falu Mods and shall b squnally numbd and nd n olumn 2 of h Dsgn FMEA fom. If povdd, a Falu Mod Donay shall b usd o dnfy h ponal falu mods. If nw falu mods a dnfd, h Falu Mod Donay shall b updad. Fo ah Ponal Falu Mod, olumns 2 (Ponal Falu Mod), 3 (Ponal Caus(s) of Falu), 4, (Oun) 5 (Ponal Eff(s) of Falu), 6 (Svy), 7 (Svy Cagoy), 8 (Funonal/ Dsgn Conol), and 9 (Mgaon) shall b ompld. Compu basd foms should b usd o od FMEA daa. 2.3.5.1. Puhasd p pas. Fo puhasd p pas, h suppl, wh possbl, shall supply h Ponal Falu Mods. 2.3.5.2. GSFC Dsgnd subsysms/omponns. Fo GSFC Dsgnd p pas, h Ponal Falu Mods shall b dnfd by h FMEA analys. 2.3.5.3 Sandadzd Ponal Falu Mods. Can sandads, handbooks, wb ss and podus suh as MIL-HDBK-338, may onan p pa falu mods. Th us of hs falu mods s nouagd. 2.3.5.4 Indmna Falu Mods. In many dsgns s possbl fo p pas o fal n an nmda o ndmna sa. Ths falu mods should b addssd n h Dsgn FMEA, spally whn h s no mgaon o dal wh hs yp of fald sa. Fo xampl, a valv ha s dsgnd o hav a bpola (opn/losd) pfoman skng n a half opn poson. 2.3.6. Ponal Falu Causs. Ponal Falu Causs a h aual falu mhansm fo h falu mod obsvd und h gvn loadng of h sysm o m und analyss. Falu mhansms and spv dvng and onbung faos shall b dnfd. Ponal Falu Causs shall b nd n Column 3 of h Dsgn FMEA fom. 2.3.7 Oun. Oun s h lav fquny o lklhood of oun of 16

h Ponal Falu Caus. Tabl 1-1 onans h song fo Oun. Th Oun valu shall b nd n olumn 4 of h Dsgn FMEA fom 2.3.8. Ponal Eff(s) of Falu. Ponal Falu Effs a h mpa of h Ponal Falu Mod on h omponn (Loal Eff); h sub-sysm (Nx Hgh Lvl Eff); and Msson o End Im (Msson Lvl Eff). Pson(s) opang o sng h omponns, sub-sysms, sysms, End Im, o Msson may b mpad by h Falu Eff as wll. Fo ah Ponal Falu Mod, on o mo Ponal Effs of Falu a h Loal, Nx Hgh and Msson Lvls shall b nd n olumn 5 of h Dsgn FMEA fom. I s possbl ha h Ponal Falu Eff may b dnfd a h Loal o Loal and Nx Hgh Lvl. In hs ass, Non should b nd as h ff a h Msson Lvl and/o Nx Hgh Lvl. 2.3.9. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 1-2. Ths valus shall b nd n olumn 6 of h Dsgn FMEA fom. 2.3.10. Mgang Faos. Fo ah Ponal Caus of Falu, h Mgang Faos (Funons/Dsgns n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and nd n olumn 7 of h Dsgn FMEA fom. 2.3.11. Mgaon. Eah Mgang Fao shall b assgnd a Mgaon ankng basd on h valus dald n Tabl 1-3. Ths valus shall b nd n olumn 8 of h Dsgn FMEA fom. 2.3.12. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Mgaon ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. All Ponal Effs of Falu shall b valuad and analyzd. Th RPN shall b nd n olumn 9 of h Dsgn FMEA fom. 2.3.13. Svy Cagoy. Th Svy Cagoy shall b nd n olumn 10 of h Dsgn FMEA fom. Th a fo Svy Cagoy a onand n Tabl 3-4. 2.3.14 Cal Ims Ls. All dsgns/p pas wh Ponal Falu Mods wh Svy Cagoy 1, 1R, 2, o 2R shall b plad on h Cal Ims Ls (s Chap 9). 2.4 Cov Aon 2.4.1. Mandaoy Cov Aon. All ponal falu mods n Svy Cagos 1, 1R and 2 a Cal and qu ov aon o du h Svy Cagoy o 2R, 3 o 4. 2.4.2 Rommndd Aon Analyss (Dson Mas). Fgus 1-3 and 1-4 a 17

Dson Mas fo dmnng whn a Rommndd Cov Aon s qud. Ths mas a fo ponal falu mods no n Svy Cagos 1, 1R, and 2. 2.4.2.1. Hgh Poy Cov Aon. Ponal falu mods ha ou n Quadan C of h max, and quadan B o D of h oh max, a hgh poy anddas fo pvnv aon. Dsons o df aon mus b doumnd n olumn 11 and appovd by Poj/Pogam Managmn. Shdul and budg may b faos o df aon. 2.4.2.2. Mdum Poy Cov Aon. Ponal falu mods ha ou n Quadans B o D of boh mas, a mdum poy anddas fo pvnv aon. Shdul and budg may b faos o df aon. 2.4.2.3. Low Poy Cov Aon. All oh ponal falu mods a low poy anddas fo pvnv aon. Wh shdul and budg pm, pvnv aons may b dvlopd and mplmnd. 2.4.3. Rommndd Aons a lad o Dsgn, Tsng, and Mgaon. Rommndd aons o b akn as a sul of h Rommndd Aon Analyss (paa. 2.4.2) shall b nd n olumn 11 of h Dsgn FMEA fom. Th nn of hs aons s o du h valus of on o mo of h Oun, Svy, and Mgaon ankngs, and hus du h valu of h RPN as wll as mov h m no a low poy quadan. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Mandaoy Cov aons shall no b pmd. No Aon Rqud fo a Hgh Poy falu shall qu Pogam Managmn and CSO appoval n wng. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/Dpamn(s). 2.4.4. Dpamn and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h Dsgn FMEA fom. 2.4.5. Dsbuon of FMEA 2.4.5.1. Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav Aon Ims o ompl. 2.4.6. Aons Takn 2.4.6.1. Th Aons Takn and h modfd Svy, Oun, and Mgaon ankngs shall b nd n olumns 12 hu 15 of h Dsgn FMEA fom. 2.4.6.2. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas duon n RPN. 2.4.6.3. To dmn h duon n RPN, h RPN s alulad as f ah ommndd aon s mplmnd. 18

2.4.6.4. Th Rommndd aons a lassfd as Mandaoy, Hgh Poy, Mdum Poy, o Low Poy. Th Rommndd aons a hn addssd whn ah agoy n od of RPN valu. Whn a Rommndd Aon s no mplmnd, ha aon shall b jusfd and appovd n wng by Pogam Managmn and h CSO. 2.4.6.5. Nw RPN. A nw RPN shall b alulad and nd n olumn 17 of h Infa FMEA fom fo vy aon akn. No should b addd ha doumn onols nd o b n pla o nsu ha pop vson s avalabl fo nspon and s updad wh avalabl daa. Do w hav a podu fo hs? 19

Rvson o Dald Dsgn Nw Dald Dsgn Ronvn FMEA Tam, f nssay (s Podu) Oganz FMEA Tam, f nssay (s Podu) Rvs Dsgn FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh Dsgn FMEA and CIL Pfom Dsgn FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda Dsgn FMEA Fgu 2-1 Dsgn FMEA Poss Flow 20

Msson: Sysm: Componn P Pa Nam Ponal Falu Mods Sysms Engn: CSO: Dsgn Engn Ponal Causs of Falu O u n Dsgn Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Mgang Faos M g a o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y M g a o n R P N Fgu 2-2 - Dsgn FMEA Fom Commn [TJD3]: Jus a hough, onsd addng a vfaon olum? 21

Chap 3 Infa FMEA 3.1 Rqumns An Infa FMEA shall b pfomd whn suffn dsgn nfomaon s avalabl o dfn h funonal nfa bwn omponns and/o sub-sysms o h fs av omponn on h sd of h nfa. In od o pfom a Infa FMEA, h followng nfomaon, as a mnmum, s qud. a) A funonal blok dagam of h m und dvlopmn bokn down o h subsysm and omponn lvl. b) A dspon of ah funon dpd n h funonal blok dagam nludng qud npus and oupus fo ah blok. ) Th dal dsgn of h omponns/sub-sysms on h sd of h nfa suffn o dnfy h fs av omponn on h sd of h nfa. d) Th mann n whh ah of h qud oupus an fal (.. low oupu, wong fquny, no moon,.). ) Th mpa o ff of loss of ah funonal nfa dpd n h funonal blok dagam and dal dsgn on h nsumn, spaaf, and/o msson. f) Th ompnsang povsons dsgnd no h m o mga h ffs of a funonal oupu falu (.. dundany, alna opang mods,.). Th Infa FMEA shall b manand as a lvng doumn houghou h lf of a Poj/Pogam. Tha s, whn hangs a mad o h nfa dsgn, h Infa FMEA shall b updad o addss hs hangs. 3.2 Applably An Infa FMEA s pfomd fo vy nfa bwn sub-sysms and bwn nsumn(s) and spaaf and bwn nsumns dung Phas B of h dvlopmn poss. 3.3 Mhodology If a Funonal FMEA has bn pfomd, h Infa FMEA may b pfomd by an FMEA analys, usually a Rlably Engn. If a Funonal FMEA has no bn pfomd, s hghly ommndd ha poons of h FMEA lad o Nx Hgh Lvl and Msson Effs b pfomd wh a Tam nludng Sysm Engnng, Msson Opaons, and Dsgn Engnng. Th FMEA Poss assums ha all npus o h av dv on h npu sd of h 22

nfa und analyss a whn spfaon and falu mods ou on a a m. (.. whn valuang a ommunaons sysm on a spaaf, h sgnals fom h Eah saon a assumd o b whn spfd lms a all ms) 3.3.1. Poss Flow. Th poss flow fo h Infa FMEA s shown n Fgu 3-1. 3.3.2. Infa FMEA Had. Th had nfomaon on h Infa FMEA fom (s Fgu 3-2) shall b ompld fo ah Infa analyzd. Th op lvl Msson, Insumn, Sysm,. nam shall b nd n h had. If a am was usd fo pa of h analyss, all Tam mmb nams and funons shall b doumnd. 3.3.3 Infa Sgnal Nam. Eah nfa und dvlopmn shall b bokn down no s onsun sgnals. Th sgnal nams shall b nd n olumn 1 of h Infa FMEA fom. 3.3.4. Sgnal Funon and Pfoman Rqumns. Th funon of ah sgnal and s pfoman qumns (.., Fquny, oupu pow, mpdan,.) shall b nd n olumn 1 of h Infa FMEA fom af h Sgnal Funon nam. 3.3.5. Ponal Falu Mods. Fo ah Sgnal Funon, all Ponal Falu Mods shall b dnfd. Th Ponal Falu Mods shall b nd n olumn 2 of h Infa FMEA fom. If povdd, a Falu Mod Donay shall b usd o dnfy h ponal falu mods. If nw falu mods a dnfd, h Falu Mod Donay shall b updad. Fo ah Ponal Falu Mod, olumns 2 (Ponal Falu Mod), 3 (Ponal Caus(s) of Falu), 4, (Oun) 5 (Ponal Eff(s) of Falu), 6 (Svy), 7 (Svy Cagoy), 8 (Funonal/ Dsgn Conol), and 9 (Mgaon) shall b ompld. Compu basd foms should b usd o od FMEA daa. 3.3.5.1. Puhasd subsysms/omponns. Fo puhasd subsysms/ omponns, h suppl, wh possbl, shall supply h Ponal Falu Mods. 3.3.5.2. GSFC Dsgnd subsysms/omponns. Fo GSFC Dsgnd subsysms/omponns, h Ponal Falu Mods shall b dnfd by h FMEA am. If Ponal Falu Mods a bng dmnd by bansomng o am valuaon, a blakboad o ompu pojo dsplay should b usd o od h Ponal Falu Mods unl h Funonal FMEA fom an b poply flld ou. 3.3.6. Ponal Falu Causs. Ponal Falu Causs a h aual falu mhansm fo h falu mod obsvd and an b a hadwa o sofwa falu. Whn pfomng an Infa FMEA, s possbl o hav mulpl Ponal Falu Causs fo a Ponal Falu Mod. Ponal Falu Causs shall b nd n Column 3 of h Infa FMEA fom. 3.3.7 Oun. Oun s h lav fquny o lklhood of oun of h Ponal Falu Caus. Tabl 1-1 onans h song fo Oun. Th Oun valu shall b nd n olumn 4 of h Infa FMEA fom 3.3.8. Ponal Eff(s) of Falu. Ponal Falu Effs a h mpa of h 23

Ponal Falu Mod on h nfa (Loal Eff); h sysm Nx Hgh Lvl Eff); and Msson o End Im (Msson Lvl Eff). Pson(s) opang o sng h omponns, sub-sysms, sysms. Fo ah Ponal Falu Mod, on o mo Loal, Nx Hgh and Msson Lvl Ponal Effs of Falu (.. duon of sn daa, loss of msson, safy,.) shall b nd n olumn 5 of h Infa FMEA fom. I s possbl ha h Ponal Falu Eff s only a h Loal o Loal and Nx Hgh Lvl. If ha s h as, Non should b nd as h ff a h Msson Lvl and/o Nx Hgh Lvl. 3.3.9. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 1-2. Ths valus shall b nd n olumn 6 of h Infa FMEA fom. 3.3.10. Mgang Faos. Fo ah Ponal Caus of Falu, h Mgang Faos (Funons/Dsgns n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and shall b nd n olumn 7 of h Infa FMEA fom. 3.3.11. Mgaon. Eah Mgang Fao shall b assgnd a Mgaon ankng basd on h valus dald n Tabl 1-3. Ths valus shall b nd n olumn 8 of h Infa FMEA fom. 3.3.12. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Mgaon ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. All Ponal Effs of Falu shall b valuad and analyzd. Th RPN s nd n olumn 9 of h Infa FMEA fom. 3.3.13. Svy Cagoy. Th Svy Cagoy shall b nd n olumn 10 of h Infa FMEA fom. Th a fo Svy Cagoy a onand n Tabl 3-4. 3.4 Cov Aon 3.4.1. Mandaoy Cov Aon. All ponal falu mods n Svy Cagos 1, 1R and 2 a Cal and qu ov aon o du h Svy Cagoy o 2R, 3 o 4. 3.4.2 Rommndd Aon Analyss (Dson Mas). Fgus 1-3 and 1-4 a Dson Mas fo dmnng whn a Rommndd Cov Aon s qud. Ths mas a fo ponal falu mods no n Svy Cagos 1, 1R, and 2. 3.4.2.1. Hgh Poy Cov Aon. Ponal falu mods ha ou n Quadan C of h max, and quadan B o D of h oh max, a hgh poy anddas fo pvnv aon. Dsons o df aon mus b doumnd n olumn 11 and appovd by Poj/Pogam Managmn and h CSO. Shdul and budg may b faos o df aon. 24

3.4.2.2. Mdum Poy Cov Aon. Ponal falu mods ha ou n Quadans B o D of boh mas, a mdum poy anddas fo pvnv aon. Shdul and budg may b faos o df aon. 3.4.2.3. Low Poy Cov Aon. All oh ponal falu mods a low poy anddas fo pvnv aon. Wh shdul and budg pm, pvnv aons may b dvlopd and mplmnd. 3.4.3. Rommndd Aons a lad o Dsgn, Tsng, and Mgaon. Rommndd aons o b akn as a sul of h Rommndd Aon Analyss (paa. 3.4.2) shall b nd n olumn 11 of h Infa FMEA fom. Th nn of hs aons s o du h valus of on o mo of h Oun, Svy, and Mgaon ankngs, and hus du h valu of h RPN as wll as mov h m no a low poy quadan. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Mandaoy Cov aons shall no b pmd. No Aon Rqud fo a Hgh Poy falu shall qu Pogam Managmn and CSO appoval n wng. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/Dpamn(s). 3.4.4. Dpamn and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h Infa FMEA fom. 3.4.4. Dsbuon of FMEA 3.4.4.1. Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav Aon Ims o ompl. 3.4.5. Aons Takn 3.4.5.1. Th Aons Takn and h modfd Svy, Oun, and Mgaon ankngs shall b nd n olumns 12 hu 15 of h Infa FMEA fom. 3.4.5.2. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas duon n RPN. 3.4.5.3. To dmn h duon n RPN, h RPN s alulad as f ah ommndd aon s mplmnd. 3.4.5.4. Th Rommndd aons a lassfd as Mandaoy, Hgh Poy, Mdum Poy, o Low Poy. Th Rommndd aons a hn addssd whn ah agoy n od of RPN valu. Whn a Rommndd Aon s no mplmnd, ha aon shall b jusfd and appovd n wng by Pogam Managmn and h CSO. 3.4.5.5. Nw RPN. A nw RPN shall b alulad and nd n olumn 17 of h Infa FMEA fom fo vy aon akn. 25

Rvson o Infa Blok Dagam Nw Infa Blok Dagam Ronvn FMEA Tam, If nssay (s podu) Oganz FMEA Tam, f nssay (s podu) Rvs Infa FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh Infa FMEA and CIL Pfom Infa FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda Infa FMEA Fgu 3-1 Infa FMEA Poss Flow 26

Msson: Sysm: Infa: Infa Sgnal Nam Ponal Falu Mods Sysms Engn: CSO: Dsgn Engn Ponal Causs of Falu O u n Infa Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Mgang Faos M g a o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y M g a o n R P N Fgu 3-2 Infa FMEA Fom 27

Chap 4 Sofwa FMEA 4.1 Rqumns A Sofwa FMEA shall b pfomd as soon as suffn nfomaon s avalabl o onsu a flow ha of h sofwa und dvlopmn. In od o pfom a Sofwa FMEA, h followng nfomaon, as a mnmum, s qud. a) A funonal blok dagam of h m und dvlopmn bokn down o h subsysm and omponn lvl. b) A dald flow ha of h Sofwa und Dvlopmn. ) A dspon of ah funon dpd n h funonal blok dagam nludng qud npus and oupus fo ah blok. d) A dspon of ah funonal blok n h sofwa flow ha. ) A dspon of how h Sofwa Flow Cha and Funonal Blok Dagam nfa and na. f) Th mann n whh ah of h qud sofwa funons an fal (.. fals o un on funon x, fals o ad mpau snso,.). g) Th mpa o ff of loss of ah funonal sofwa blok dpd n h sofwa flow ha on h nsumn, spaaf, and/o msson. (h mpas o ffs may b dvlopd dung a am appoah o pfomng h Sofwa FMEA) h) Th ompnsang povsons dsgnd no h m o mga h ffs of a funonal sofwa blok falu (.. dundany, alna opang mods,.). A od ln by od ln FMEA may b nssay fo sofwa moduls ha pfom al funons. In ha as, ah ln of od shall hav suffn annoad dspon o fala a poduv FMEA. Wh sofwa funonal blok s usd n hs podu, sofwa ln of od shall b subsud. Th Sofwa FMEA shall b manand as a lvng doumn houghou h lf of a Poj/Pogam. Tha s, whn hangs a mad o h sofwa flow ha, h Sofwa FMEA shall b updad o addss hs hangs. 4.2 Applably A Sofwa FMEA s pfomd fo vy Msson, Spaaf, Insumn, Gound Sysm, sysms, sub-sysms, sofwa and omponn dung Phas B of h 28

dvlopmn poss. 4.3 Mhodology Th Sofwa FMEA shall whnv possbl b pfomd by an FMEA Tam onssng of a Rlably Engn, Sysms Engn, Sofwa Engn, Elal Engn, I&T Engn, and Msson Opaons Engn. 4.3.1. Poss Flow. Th poss flow fo h Sofwa FMEA s shown n Fgu 3-1. 4.3.2. Sofwa FMEA Had. Th had nfomaon on h Sofwa FMEA fom (s Fgu 4-2) shall b ompld fo ah Sofwa Flow Cha analyzd. Th op lvl Msson, Insumn, Sysm,. nam shall b nd n h had. All Tam mmb nams and funons shall b doumnd. 4.3.3 Sofwa Funonal Blok Nam. Eah sofwa modul und dvlopmn shall b bokn down no s onsun sofwa funonal bloks. Th subsysm and omponn nams shall b nd n olumn 1 of h Sofwa FMEA fom. 4.3.4. Sofwa Funonal Blok Rqumns. Th qumns fo ah sofwa funonal blok shall b nd n olumn 1 of h Funonal FMEA fom af h Sofwa Funonal Blok Nam. 4.3.5. Ponal Falu Mods. Fo ah Sofwa Funonal Blok, all Ponal Falu Mods shall b dnfd. Th Ponal Falu Mods shall b nd n olumn 2 of h Sofwa FMEA fom. If povdd, a Falu Mod Donay shall b usd o dnfy h ponal falu mods. If nw falu mods a dnfd, h Falu Mod Donay shall b updad. Fo ah Ponal Falu Mod, olumns 2 (Ponal Falu Mod), 3 (Ponal Caus(s) of Falu), 4, (Oun) 5 (Ponal Eff(s) of Falu), 6 (Svy), 7 (Svy Cagoy), 8 (Funonal/ Dsgn Conol), and 9 (Mgaon) shall b ompld. Compu basd foms should b usd o od FMEA daa. 4.3.6. Ponal Falu Causs. Ponal Falu Causs a h aual sofwa fauls fo h falu mod ha an b obsvd and an b a hadwa o sofwa ompably, sofwa odng, o opang podu falu. Whn pfomng a Sofwa FMEA, s possbl o hav mulpl Sofwa fauls fo a Ponal Falu Mod. Ponal Falu Causs a nd n Column 3 of h sofwal FMEA fom. 4.3.7 Oun. Oun s h lklhood of h Ponal Falu Caus oung. Tabl 1-1 onans h song fo Oun. Th Oun valu s nd n olumn 4 of h Sofwa FMEA fom 4.3.8. Ponal Eff(s) of Falu. Ponal Falu Effs a h mpa of h Ponal Falu Mod on h sub-sysm/omponn (Loal Eff); h sysm (fo sub-sysm) o sub-sysm (fo omponn) (Nx Hgh Lvl Eff); and Msson o End Im (Msson Lvl Eff). Pson(s) opang o sng h omponns, subsysms, sysms, End Im, o Msson may b mpad by h Falu Eff as wll. 29

Fo ah Ponal Falu Mod, on o mo Ponal Effs of Falu (.. duon of sn daa, loss of msson, safy,.) shall b nd n olumn 5 of h Sofwa FMEA fom. I s possbl ha h Ponal Falu Eff s only a h Loal o Loal and Nx Hgh Lvl. If ha s h as, Non should b nd as h ff a h Msson Lvl and/o Nx Hgh Lvl. 4.3.9. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 1-2. Ths valus shall b nd n olumn 6 of h Sofwa FMEA fom. 4.3.10. Mgang Faos. Fo ah Ponal Caus of Falu, h Mgang Faos (Funons/Dsgns n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and nd n olumn 7 of h Sofwa FMEA fom. 4.3.11. Mgaon. Eah Mgang Fao shall b assgnd a Mgaon ankng basd on h valus dald n Tabl 1-3. Ths valus shall b nd n olumn 8 of h Sofwa FMEA fom. 4.3.12. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Mgaon ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. All Ponal Effs of Falu shall b valuad and analyzd. Th RPN s nd n olumn 9 of h Sofwa FMEA fom. 4.3.13. Svy Cagoy. Th Svy Cagoy shall b nd n olumn 10 of h Sofwa FMEA fom. Th a fo Svy Cagoy a onand n Tabl 1-4. 4.4 Cov Aon 4.4.1. Mandaoy Cov Aon. All ponal falu mods n Svy Cagos 1, 1R and 2 a Cal and qu ov aon o du h Svy Cagoy o 2R, 3 o 4. 4.4.2 Rommndd Aon Analyss (Dson Mas). Fgus 1-3 and 1-4 a Dson Mas fo dmnng whn a Rommndd Cov Aon s qud. Ths mas a fo ponal falu mods no n Svy Cagos 1, 1R, and 2. 4.4.2.1. Hgh Poy Cov Aon. Ponal falu mods ha ou n Quadan C of h max, and quadan B o D of h oh max, a hgh poy anddas fo pvnv aon. Dsons o df aon mus b doumnd n olumn 11 and appovd by Poj/Pogam Managmn. Shdul and budg may b faos o df aon. 4.4.2.2. Mdum Poy Cov Aon. Ponal falu mods ha ou n Quadans B o D of boh mas, a mdum poy anddas fo pvnv aon. Shdul and budg may b faos o df aon. 30

4.4.2.3. Low Poy Cov Aon. All oh ponal falu mods a low poy anddas fo pvnv aon. Wh shdul and budg pm, pvnv aons may b dvlopd and mplmnd. 4.4.3. Rommndd Aons a lad o Dsgn, Tsng, and Mgaon. Rommndd aons o b akn as a sul of h Rommndd Aon Analyss (paa. 4.4.2) shall b nd n olumn 11 of h Sofwa FMEA fom. Th nn of hs aons s o du h valus of on o mo of h Oun, Svy, and Mgaon ankngs, and hus du h valu of h RPN as wll as mov h m no a low poy quadan. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Mandaoy Cov aons shall no b pmd. No Aon Rqud fo a Hgh Poy falu shall qu Pogam Managmn and CSO appoval n wng. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/Dpamn(s). 4.4.4. Dpamn and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h Sofwa FMEA fom. 4.4.5. Dsbuon of FMEA 4.4.5.1. Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav Aon Ims o ompl. 4.4.6. Aons Takn 4.4.6.1. Th Aons Takn and h modfd Svy, Oun, and Mgaon ankngs shall b nd n olumns 12 hu 15 of h Sofwa FMEA fom. 4.4.6.2. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas duon n RPN. 4.4.6.3. To dmn h duon n RPN, h RPN s alulad as f ah ommndd aon s mplmnd. 4.4.6.4. Th Rommndd aons a lassfd as Mandaoy, Hgh Poy, Mdum Poy, o Low Poy. Th Rommndd aons a hn addssd whn ah agoy n od of RPN valu. Whn a Rommndd Aon s no mplmnd, ha aon shall b jusfd and appovd n wng by Pogam Managmn and h CSO. 4.4.6.5. Nw RPN. A nw RPN shall b alulad and nd n olumn 17 of h Sofwa FMEA fom fo vy aon akn. 31

Rvson o Sofwa Flow Cha Nw Sofwa Flow Cha Ronvn FMEA Tam Oganz FMEA Tam Rvs Sofwa FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh Sofwa FMEA and CIL Pfom Sofwa FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda Sofwa FMEA Fgu 4-1 Sofwa FMEA Poss Flow 32

Msson: Sysm: Sofwa Modul: Sofwa Funonal Blok Nam Ponal Falu Mods Sysms Engn: CSO: Dsgn Engn Ponal Causs of Falu O u n Sofwa Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Mgang Faos M g a o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y M g a o n R P N Fgu 4-1 Sofwa FMEA Fom 33

Chap 5 Gound Suppo Equpmn (GSE) FMEA 5.1 Rqumns A GSE FMEA shall b pfomd as soon as suffn nfomaon s avalabl o dfn h GSE and h nfa o h m und dvlopmn. In od o pfom a GSE FMEA, h followng nfomaon, as a mnmum, s qud. a) Funonal blok dagams of h m und dvlopmn and GSE bokn down o h subsysm and omponn lvl. b) A dspon of ah funon dpd n h funonal blok dagams nludng qud npus and oupus fo ah blok. ) Th dald dsgn dspon of h nfa bwn GSE and h m und dvlopmn nludng h mann n whh ah of h nfad us, flud sysms, o mhansms bwn h Im und dvlopmn and GSE an fal (.. low oupu, wong fquny, no moon,.). d) Th ompnsang povsons dsgnd no h GSE and m und dvlopmn o po h m und dvlopmn fom h ffs of an nfa falu. Th GSE FMEA shall b manand as a lvng doumn houghou h lf of a Poj/Pogam. Tha s, whn hangs a mad o h GSE and/o Im und dvlopmn, h GSE FMEA shall b updad o addss hs hangs. 5.2 Applably A GSE FMEA s pfomd fo vy m of flgh hadwa ha wll undgo s usng h usom o off h shlf GSE po o h Ingaon and Ts (I&T) phas of h Poj/Pogam. 5.3 Mhodology Th GSE FMEA shall whnv possbl b pfomd by an FMEA Tam onssng of a Rlably Engn, Sysms Engn, Elal Engn, Mhanal Engn, and I&T Engn. 5.3.1. Poss Flow. Th poss flow fo h GSE FMEA s shown n Fgu 5-1. 5.3.2. GSE FMEA Had. Th had nfomaon on h GSE FMEA fom (s Fgu 5-2) shall b ompld fo ah GSE/Im und Dvlopmn Infa analyzd. Th op lvl Msson, Pogam, o Poj. nam shall b nd n h had. All Tam mmb nams and funons shall b doumnd. 34

5.3.3 GSE Funonal Blok Nam. Eah GSE/Im und dvlopmn Infa shall b bokn down no s onsun funonal bloks. Th GSE Funonal Blok nams shall b nd n olumn 1 of h GSE FMEA fom. 5.3.4. GSE Funonal Blok Funon and Pfoman Rqumns. Th funon of ah GSE Funonal Blok and s pfoman qumns (.., Fquny, oupu pow, Fld of Vw,.) shall b nd n olumn 1 of h GSE FMEA fom af h GSE Funonal Blok nam. 5.3.5. Ponal Falu Mods. Fo ah GSE Funonal Blok, all Ponal Falu Mods shall b dnfd. Th Ponal Falu Mods shall b nd n olumn 2 of h GSE FMEA fom. If povdd, a Falu Mod Donay shall b usd o dnfy h ponal falu mods. If nw falu mods a dnfd, h Falu Mod Donay shall b updad. Fo ah Ponal Falu Mod, olumns 2 (Ponal Falu Mod), 3 (Ponal Caus(s) of Falu), 4, (Oun) 5 (Ponal Eff(s) of Falu), 6 (Svy), 7 (Svy Cagoy), 8 (Mgang Faos), and 9 (Mgaon) shall b ompld. Compu basd foms should b usd o od FMEA daa. 5.3.5.1. Puhasd GSE. Fo puhasd GSE, h suppl, wh possbl, shall supply h Ponal Falu Mods. 5.3.5.2. GSFC Dsgnd GSE. Fo GSFC Dsgnd GSE, h Ponal Falu Mods shall b dnfd by h FMEA am. 5.3.6. Ponal Falu Causs. Ponal Falu Causs a h aual falu mhansm fo h falu mod obsvd and an b a hadwa, sofwa, o opang podu falu. Whn pfomng a GSE FMEA, s possbl o hav mulpl Ponal Falu Causs fo a Ponal Falu Mod. Ponal Falu Causs a nd n Column 3 of h GSE FMEA fom. 5.3.7 Oun. Oun s h lav fquny o lklhood of oun of h Ponal Falu Caus. Tabl 1-1 onans h song fo Oun. Th Oun valu s nd n olumn 4 of h GSE FMEA fom 5.3.8. Ponal Eff(s) of Falu. Ponal Falu Effs a h mpa of h Ponal Falu Mod on h sub-sysm/omponn (Loal Eff); h sysm (fo sub-sysm) o sub-sysm (fo omponn) (Nx Hgh Lvl Eff); and Msson o End Im (Msson Lvl Eff). Pson(s) opang o sng h omponns, subsysms, sysms, End Im, o Msson may b mpad by h Falu Eff as wll. Fo ah Ponal Falu Mod, on o mo Ponal Effs of Falu (.. loss of omponn, loss of sysm,.) shall b nd n olumn 5 of h GSE FMEA fom. I s possbl ha h Ponal Falu Eff s only a h Loal o Loal and Nx Hgh Lvl. If ha s h as, Non should b nd as h ff a h Msson Lvl and/o Nx Hgh Lvl. 5.3.9. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 5-2. 35

Ths valus shall b nd n olumn 6 of h GSE FMEA fom. 5.3.10. Mgang Faos. Fo ah Ponal Caus of Falu, h Mgang Faos (Funons/Dsgns n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and nd n olumn 7 of h GSE FMEA fom. 5.3.11. Mgaon. Eah Mgang Fao shall b assgnd a Mgaon ankng basd on h valus dald n Tabl 1-3. Ths valus shall b nd n olumn 8 of h GSE FMEA fom. 5.3.12. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Mgaon ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. All Ponal Effs of Falu shall b valuad and analyzd. Th RPN s nd n olumn 9 of h GSE FMEA fom. 5.3.13. Svy Cagoy. Th Svy Cagoy shall b nd n olumn 10 of h GSE FMEA fom. Th a fo Svy Cagoy a onand n Tabl 1-4. 5.4 Cov Aon 5.4.1. Mandaoy Cov Aon. All ponal falu mods n Svy Cagos 1, 1R and 2 a Cal and qu ov aon o du h Svy Cagoy o 2R, 3 o 4. 5.4.2 Rommndd Aon Analyss (Dson Mas). Fgus 1-3 and 1-4 a Dson Mas fo dmnng whn a Rommndd Cov Aon s qud. Ths mas a fo ponal falu mods no n Svy Cagos 1, 1R, and 2. 5.4.2.1. Hgh Poy Cov Aon. Ponal falu mods ha ou n Quadan C of h max, and quadan B o D of h oh max, a hgh poy anddas fo pvnv aon. Dsons o df aon mus b doumnd n olumn 11 and appovd by Poj/Pogam Managmn. Shdul and budg may b faos o df aon. 5.4.2.2. Mdum Poy Cov Aon. Ponal falu mods ha ou n Quadans B o D of boh mas, a mdum poy anddas fo pvnv aon. Shdul and budg may b faos o df aon. 5.4.2.3. Low Poy Cov Aon. All oh ponal falu mods a low poy anddas fo pvnv aon. Wh shdul and budg pm, pvnv aons may b dvlopd and mplmnd. 5.4.3. Rommndd Aons a lad o Dsgn, Tsng, and Mgaon. Rommndd aons o b akn as a sul of h Rommndd Aon Analyss (paa. 6.4.2) shall b nd n olumn 11 of h Funonal FMEA fom. Th nn of 36

hs aons s o du h valus of on o mo of h Oun, Svy, and Mgaon ankngs, and hus du h valu of h RPN as wll as mov h m no a low poy quadan. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Mandaoy Cov aons shall no b pmd. No Aon Rqud fo a Hgh Poy falu shall qu Pogam Managmn and CSO appoval n wng. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/Dpamn(s). 5.4.4. Dpamn and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h GSE FMEA fom. 5.4.4. Dsbuon of FMEA 5.4.4.1. Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav Aon Ims o ompl. 5.4.5. Aons Takn 5.4.5.1. Th Aons Takn and h modfd Svy, Oun, and Mgaon ankngs shall b nd n olumns 12 hu 15 of h GSE FMEA fom. 5.4.5.2. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas duon n RPN. 5.4.5.3. To dmn h duon n RPN, h RPN s alulad as f ah ommndd aon s mplmnd. 5.4.5.4. Th Rommndd aons a lassfd as Mandaoy, Hgh Poy, Mdum Poy, o Low Poy. Th Rommndd aons a hn addssd whn ah agoy n od of RPN valu. Whn a Rommndd Aon s no mplmnd, ha aon shall b jusfd and appovd n wng by Pogam Managmn and h CSO. 5.4.5.5. Nw RPN. A nw RPN shall b alulad and nd n olumn 17 of h GSE FMEA fom fo vy aon akn. 37

Rvson o GSE/ Im Und Dvlopmn Infa Nw GSE/Im Und Infa Infa Ronvn FMEA Tam Oganz FMEA Tam Rvs GSE FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh GSE FMEA and CIL Pfom GSE FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda GSE FMEA Fgu 5-1 GSE FMEA Poss 38

Msson: Sysm: GSE Infa: GSE Funonal Blok Nam Ponal Falu Mods Sysms Engn: CSO: I&T Engn Ponal Causs of Falu O u n GSE Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Mgang Faos M g a o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y M g a o n R P N Fgu 5-2 GSE FMEA Fom 39

Tabl 5-2 - Svy Rankng Ca Svy = (Hadwa Impa + Los Msson Tm) * Safy/Msson Loss Hadwa Impa (1-5) Eff Ca: Svy of Eff Rang Vy Sous Hadwa >75% loss of Msson Capably 5 Capably Eff Sous Hadwa Capably >50% loss of Msson Capably 4 Eff Moda Hadwa Capably >25% loss of Msson Capably 3 Eff Mno Hadwa Capably >10% loss of Msson Capably 2 Eff No Hadwa Capably Eff No mpa on Msson Capably 1 Los Ts Tm (1-5) Vy Hgh Los Ts m Ga han 30 days los Ts m 5 Hgh Los Ts m Ga han 15 days los Ts m 4 Moda Los Ts m Ga han 7 days los Ts m 3 Low Los Ts m Ga han 1 days los Ts m 2 No Los Ts m No Los Ts Tm 1 Safy o Msson Loss (1-10) Sgnfan Safy Hazad o Toal Immda lf o lmb hanng hazad o 10 Loss of Msson Mno Safy Hazad, Majo Spaaf Damag o Majo Loss of Msson Capabls Sgnfan Spaaf Damag o Loss oal loss of msson Mno Injuy Hazad (no ha o lf o lmb) Majo (50<75%) Sgnfan (25<50%) Spaaf damag o Msson Loss 5 3 No Hazads o Loss of Msson No safy ssu o sgnfan mahny damag. 1 40

Chap 6 Poss FMEA 6.1. Poss FMEA Rqumns A Poss FMEA shall b pfomd whn h subj Poss and/o Podu s suffnly dvlopd o laly dfn h poss npus, asks, and xpd ouoms. In od o pfom a Poss FMEA, h followng nfomaon, as a mnmum, s qud. a) A dald sp by sp podu and flow ha fo h Poss. b) A dspon of pupos of ah sp n h podu nludng qud npus and oupus. ) Th mann n whh ah of h qud sps an fal (.. mpop oqu appld, wong s qupmn, no squn of opaon,.). d) Th mpa o ff of falu o ahv ah oupu dsbd n h podu on h m o funon bng subjd o h Poss. ) Th ompnsang povsons dsgnd no h Poss o mga h ffs of a poss sp falu (.. o poofng, dundan hkng,.). Th Poss FMEA shall b manand as a lvng doumn houghou h lf of h Poss/Podu. Tha s, whn hangs a mad o h Poss o Podu, h Poss FMEA shall b updad o addss hs hangs. 6.2 Applably A Poss FMEA shall b pfomd fo vy Opang, Svng, Manufaung, Inspon, Ts, Rpa, Handlng, and Lf Podu/Poss ha affs Flgh Hadwa. A Poss FMEA shall b pfomd fo vy Podu/Poss ha has Safy mplaons. A Poss FMEA should b pfomd fo all oh podus and posss usd a NASA GSFC o du was and mpov ffny. 6.3 Mhodology Th Poss FMEA shall whnv possbl b pfomd by an FMEA Tam onssng of a Rlably Engn, Sysms Engn, Qualy Engn, I&T Engn, Safy Engn, and Manufaung Engn. Ths am should also nlud h Poss Own, Poss Suppl and Poss Cusom and oh manufaung psonal dmd nssay by h am. Th FMEA Poss assums falu mods ou on a a m. 41

6.3.1 FMEA Poss Flow. Th poss flow fo h Poss FMEA podu s shown n Fgu 6-1. 6.3.2. Poss FMEA Had. Th had nfomaon on h Poss FMEA fom (s Fgu 6-2) shall b ompld fo ah Poss analyzd. Whn applabl, h op lvl Msson, Insumn, Sysm,. nam shall b nd n h had. All Tam mmb nams and funons shall b doumnd. 6.3.3. Poss/Podu Nam. Th poss/podu nam shall b nd n olumn 1 of h Poss FMEA fom. 6.3.4 Poss Funon and Pfoman Rqumns. Th funon of ah poss and s pfoman qumns (.., oupu, ffns, manpow and maal qumns) shall b nd n olumn 1 of h Poss FMEA fom af h Poss nam. 6.4. Ponal Falu Mods. Fo ah poss, all Ponal Falu Mods shall b dnfd. Th Ponal Falu Mods shall b nd n olumn 2 of h Poss FMEA fom. 6.5. FMEA Poss. Fo ah Ponal Falu Mod, olumns 2, 3, 4, 5, 6, 7, 8, and 9 shall b ompld. 6.5.1. Ponal Causs(s) of Falu. Fo ah Ponal Falu Mod, on o mo Ponal Causs of Falu shall b nd n olumn 3 of h Poss FMEA fom. Ths Ponal Causs of Falu shall b spf os o malfunons ha an b dsbd n ms of somhng ha an b od o onolld n h manufaung nvonmn.. 6.5.2. Oun. Eah Ponal Caus of Falu shall b assgnd an Oun ankng basd on h valus dald n Tabl 4-1. Ths valus shall b nd n olumn 4 of h Poss FMEA fom. 6.5.3. Ponal Eff(s) of Falu. Fo ah Ponal Falu Mod, on o mo Ponal Effs of Falu (.. # of hous wok o xa asks, sap, safy, nvonmnal) shall b nd n olumn 5 of h Poss FMEA fom. 6.5.4. Svy. Eah Ponal Eff of Falu shall b assgnd a Svy ankng. Th Svy ankng shall b alulad basd on h valus dald n Tabl 6-2. Ths valus shall b nd n olumn 6 of h Innal Poss FMEA fom. 6.5.5. Svy Classfaon. If h svy s ad 9 o 10, n h ls OS n olumn 7 of h Poss FMEA fom. Ths falu mods a safy lad and mus b addssd. 6.5.6. Cun Poss Conols. Fo ah Ponal Caus of Falu, h Cun Poss Conols (mhansms n pla o d, pvn, o mnmz h mpa of h falu) shall b dnfd and nd n olumn 8 of h Poss FMEA fom. 42

6.5.7. Don. Eah Cun Poss Conol shall b assgnd a Don ankng basd on h valus dald n Tabl4-3. Ths valus shall b nd n olumn 9 of h Poss FMEA fom. 6.5.8. Rsk Poy Numb (RPN). Th RPN shall b h podu of h Oun, Svy, and Don ankngs. Th RPN shall b usd fo applaon of a Pao analyss o dmn h od n whh ommndd aons shall b dvlopd o addss Ponal Falu Mods and Causs o mpov h lably of h qupmn. All Ponal Effs of Falu shall b valuad and analyzd. Th RPN s nd n olumn 10 of h Poss FMEA fom. 6.5.9. Rommndd Aons lad o Poss Dsgn, Podus, Opaon, and Falu Don. Rommndd aons o b akn as a sul of h RPN analyss shall b nd n olumn 11 of h Poss FMEA fom. Th nn of hs aons s o du h valus of on o mo of h Oun, Svy, and Pvnon ankngs, and hus du h valu of h RPN. Th mus b an ny mad n hs olumn. If s h dmnaon of h FMEA Tam ha no aon s qud, "No Aon Rqud" mus b nd. "No Aon Rqud" dsons fo Cal falus shall b jusfd. Th Rommndd Aons shall b ad as Rquss fo Aon (RFAs) by h Rsponsbl Indvdual(s)/ Dpamn(s). 6.5.10. Aa and/o Indvdual Rsponsbl and a Complon Da. A dpamn and/o ndvdual sponsbl and a omplon da shall b assgnd o mplmn h Rommndd Aon(s). Ths nfomaon shall b nd n olumn 12 of h Poss FMEA fom. 6.5.11. Dsbuon of FMEA Th FMEA shall b dsbud o all mmbs of h FMEA Tam and o all Rsponsbl Indvdual(s)/Dpamn(s) who hav RFAs o ompl. 6.5.12. Aons Takn Th Aons Takn and h modfd Svy, Oun, and Don ankngs shall b nd n olumns 12 hu 15 of h Poss FMEA fom. Th "Aons Takn" shall b pozd by aomplshng h aons n od of gas RPN. In all ass, al falus shall b addssd fs. I s possbl o hav a Rommndd Aon and no mplmn ha aon du o oh onsdaons, suh as Envonmnal Impa. Nw RPN. A nw RPN shall b alulad and nd n olumn 16 of h Innal Poss FMEA fom fo vy aon akn. 43

Tabl 6-1 - Oun Rankng Ca Lklhood of Ca: Possbl Falu Ras/Pobably of Falu Rang Oun Exmly Hgh Pobably of Falu Dung Poss >0.1 10 Vy Hgh Pobably of Falu Dung Poss 0.1 < 0.05 9 Hgh Pobably of Falu Dung Poss 0.05 < 0.01 8 Modaly Hgh Pobably of Falu Dung Poss 0.01 < 0.005 7 Moda Pobably of Falu Dung Poss 0.005 < 0.001 6 Modaly Low Pobably of Falu Dung Poss 0.001 < 0.0005 5 Low Pobably of Falu Dung Poss 0.0005 < 0.0001 4 Vy Low Pobably of Falu Dung Poss 0.0001 < 0.00005 3 Exmly Low Pobably of Falu Dung Poss 0.00005 < 0.00001 2 Rmo Pobably of Falu Dung Poss <0.00001 1 44

Tabl 6-2 - Svy Rankng Ca Svy = (Msson Impa + Los Shdul Tm) * Safy/Msson Loss Msson Impa (1-5) Eff Ca: Svy of Eff Rang Vy Sous Msson Capably >75% loss of Msson Capably 5 Eff Sous Msson Capably Eff >50% loss of Msson Capably 4 Moda Msson Capably >25% loss of Msson Capably 3 Eff Mno Msson Capably Eff >10% loss of Msson Capably 2 No Msson Capably Eff No mpa on Msson Capably 1 Los Shdul Tm (1-5) Vy Hgh Los Shdul m Ga han 30 days los Shdul m 5 Hgh Los Shdul m Ga han 15 days los Shdul m 4 Moda Los Shdul m Ga han 7 days los Shdul m 3 Low Los Shdul m Ga han 1 days los Shdul m 2 No Los Shdul m No Los Shdul Tm 1 Safy o Msson Loss (1-10) Sgnfan Safy Hazad o Toal Immda lf o lmb hanng hazad o 10 Loss of Msson Mno Safy Hazad, Majo Spaaf Damag o Majo Loss of Msson Capabls Sgnfan Spaaf Damag o Loss oal loss of msson Mno Injuy Hazad (no ha o lf o lmb) Majo (50<75%) Sgnfan (25<50%) Spaaf damag o Msson Loss 5 3 No Hazads o Loss of Msson No safy ssu o sgnfan mahny damag. 1 45

Tabl 6-3 - Don Rankng Ca Donj Ca Lklhood of Don by Poss Dsgn o Conols Rang Non Th s no Don of h Falu Mod o s subsqun 10 Falu Eff Vy Rmo Th s a vy mo pobably h Dsgn wll d h 9 Falu Mod o s subsqun Falu Eff (lss han 10% pobably fo don) Rmo Th s a mo pobably h Dsgn wll d h Falu 8 Mod o s subsqun Falu Eff (10 > 20% pobably fo Don) Vy Low Th s a vy low han h Dsgn wll d h Falu 7 Mod o s subsqun Falu Eff (20 > 30% pobably fo don) Low Th s a Low pobably h Dsgn wll d h Falu 6 Mod o s subsqun Falu Eff (30 > 40% pobably fo don) Moda Th s a Moda pobably h Dsgn wll d h Falu 5 Mod o s subsqun Falu Eff (40 > 60% pobably fo don) Modaly Hgh Th s a Modaly Hgh pobably h Dsgn wll D h 4 Falu Mod o s subsqun Falu Eff (60 > 80% pobably fo Don) Hgh Th s a Hgh pobably h Dsgn wll d h Falu 3 Mod o s subsqun Falu Eff (80 > 90% pobably fo don) Vy Hgh Th s a Vy Hgh pobably h Dsgn wll d and/o 2 anpa h Falu Mod o s subsqun Falu Eff (90 > 99% pobably fo mgaon) Almos Can Th s an almos an pobably h Dsgn wll d and/o anpa h Falu Mod o s subsqun Falu Eff (> 99% pobably fo don) 1 46

Rvson o Poss/ Podu Nw/Exsng Poss Podu Ronvn FMEA Tam Oganz FMEA Tam Rvs Poss FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Publsh Poss FMEA and CIL Pfom Poss FMEA & Dvlop CIL and Ls of Mandaoy and Pozd Cov Aons Dvlop Cov Aons Implmn Cov Aons and Upda Poss FMEA Fgu 6-1 Poss FMEA Poss Flow 47

Msson: Sysm: Poss/Podu: Poss/ Podu Sp Ponal Falu Mods Sysms Engn: Poss Own Poss Cusom Ponal Causs of Falu O u n Poss Falu Mods and Effs Analyss FMEA Da: Ponal Effs of Falu S v y S C a v g o y y Cun Poss Conols D o n R P N FMEA Tam: Rommndd Aons Dpamn/ Indvdual Rsponsbl & Complon Da Aon Rsuls Aons Takn O u n S v y D o n R P N Fgu 6-2 Poss FMEA Fom 48

Chap 7 Falu Mods, Effs and Caly Analyss (FMECA) 7.1 Rqumns In addon o Dsgn FMEA Rqumns, h followng nfomaon s nssay o pfom an FMECA. Rlably Pdon wh falu as povdd fo ah onsun p pa. Quanav valuaon of h popoon of h falu a assgnd o ah falu mod fo a p pa. 7.2 Applably FMECA shall b pfomd whn spfally qud by h qumns of a Poj/Pogam. Th pfoman of FMECA n pla of Dsgn FMEA and CIL should b a and an xpon o nomal podus. An FMECA s pfomd whn s nssay o quanfy h spf falu a of ah falu mod. 7.3 Mhodology Eah FMECA shall b pfomd n aodan wh h mhodology of MIL-STD-1629. 7.4 Cov Aon All al ms dnfd n h FMECA shall hav Mandaoy Cov Aon akn. Chap 8 Cal Ims Ls (CIL) 8.1 CRITICAL ITEMS CRITERIA CIL shall onss of hos falu mods dnfd n h FMEA ha m h a spfd blow: All Caly Cagoy 1, 1R, and 2 ms. All Caly Cagoy 2R ms unl h dundany appoah s valdad as suffn o assu ha falu of h dundan lmns s hghly unlkly hough pobably analyss and falu hsoy valuaon. 8.2 RETENTION RATIONALE Fo ah m on h CIL, ha s no addssd by havng a Cov Aon akn, h shall b a non aonal ppad whh onans daa ha suppos h pms ha h sk psnd by nluson of h m n h dsgn has bn mnmzd by a dald valuaon of pobably of oun; pop dsgn onols, nspons, and ss; and ha no advs falu hsoy xss. Th aonal also wll 49

onan daa ha dsbs opaonal onsans ausd by oun of h falu, and dsb h masus akn o assu ha h funon s soabl on ob. Th aonal shall addss h followng aas: 8.2.1 DESIGN - Idnfy spf dsgn faus ha mnmz h pobably of oun of h falu mod and s auss. Wh applabl, la h dsgn faus o h spf auss. Typal onollng faus nlud faos of safy, us of spal maals, unqu physal/hmal haass/pops, al dmnsons, and oh masuabl paams und dsgn onol. Dsb h dundany onfguaon, f applabl, and ls h manng suss pahs af fs falu. Dsuss pfoman dgadaon, f any, as falus ou o as lf lms xp. 8.2.2 TEST - Idnfaon of spf ss aomplshd o d falu mods and auss dung lf s, apan ss, faon ss, and plaunh and on-ob hkou ss. Lf ss should b ondud o falu o sasally dsgnd fo a 2X lf valdaon onsdng an appopa sampl sz and onfdn lm. 8.2.3 INSPECTION - Idnfaon of spf nspon a nludd o show ha spf falu mod auss a no nadvnly manufaud no h hadwa o ha hadwa has no dgadd. 8.2.4 FAILURE HISTORY - Povd a summay of all falus fo whh ov aon (dsgn hang, apan s hang,.) has suld n h lmnaon of falus (n hs mod). Th m fam fo h summay should sa wh apan s hough h un da. A lsng of all lvan falus should b oband hough h Poblm Rpong Sysm. 8.2.5 OPERATIONAL USE - Dsb opaons o mga o lm h hadwa s falu ff, suh as h followng: malfunon podus, aons ha may b akn by h msson opaons (o w on mannd mssons) followng h falu, anng, onsans on opaons, and on-ob hkou aons ha ould d mpop opaon/loss of dundany. Whn appovd opaonal wokaounds a ulzd, opaonal wokaounds shall b dfnd o h lvl nssay fo mplmnaon and h opaonal podu shall b valdad and and fo po o flgh. If, a h m of CIL baslnng, h opaonal podu s no valdad, h CIL non aonal shall fl h fowad wok. 8.3 CRITICAL ITEMS LIST REPORT - Th CIL po shall onan, as a mnmum, h ms n lsd blow: a) An noduon povdng ons samns on h objvs of h po. b) A samn of sop dsbng h Componn, Sofwa Modul, Funon, Subsysm, Sysm, and/o Msson onand n h CIL. 50

) A CIL ndx ha povds a on-ln summay of al ms. Th ndx shall nlud, as a mnmum, h FMEA numb, m nam, pa numb, quany, and wos as svy agoy fo ah falu mod. d) Rommndaons fo lmnaon fom h CIL and appoah o ahv lmnaon. ) Rfn doumns, nludng analyss pfomd o jusfy non of h al ms. f) An aonym and abbvaon ls and dfnons of spal ms usd. All falu mods ha a assgnd o Svy Cagos 1, 1R, 2, and 2R, shall b mzd on a Cal Ims Ls (CIL) and manand wh h FMEA po. Raonal fo anng h ms shall b nludd on h CIL. Th FMEA and CIL shall b doumnd and pod n aodan wh h RMP. Chap 9 Ponal Falu Mod Donay Th Rlably and Rsk Analyss Banh shall hav h sponsbly o oll avalabl nfomaon o dvlop and manan a Falu Mod Donay. Ths donay shall onan Ponal Falu Mods fo Funons, omponns, sofwa, human aons, o fala h pfoman of FMEA. Th donay shall b manand n lon foma o fala ass. Th ably o add o and modfy h donay shall b sd o assu h ngy of h nfomaon. Chap 10 Alna FMEA Podus 10.1 MIL-STD-1629 - Podus fo Pfomng a Falu Mods, Effs, and Caly Analyss 10.2 SAE J1739 - Ponal Falu Mod and Effs Analyss n Dsgn (Dsgn FMEA), Ponal Falu Mod and Effs Analyss n Manufaung 10.3 SSP 30234 - Falu Mods and Effs Analyss and Cal Ims Ls Rqumns fo Spa Saon 51