Upgrades Said To Reduce Assembly Time By 46 Percent

NASA and aerospace contractor ATK recently held an event to highlight progress made in manufacturing the first ground test motor and cost-saving process upgrades for manufacturing the solid rocket booster for NASA's Space Launch System (SLS). ATK says the changes have reduced assembly time by approximately 46 percent, saving millions of dollars in projected costs for the SLS system.

ATK's Value Stream Mapping (VSM) process, which is a company-wide business practice, allowed the employees to identify inefficient processes, procedures and requirements to help reach the target condition. Through this process, ATK identified more than 400 changes and improvements, which NASA approved. "As we were challenged with decreased budgets and a more streamlined workforce, we knew we had to make changes in order to stay competitive, but we also know the importance of ensuring we deliver a safe and reliable product for America's human space flight program," said Charlie Precourt, general manager and vice president of ATK's Space Launch Division. "Through the VSM process we are delivering an even higher-quality product for less cost than originally envisioned for the SLS program."

Many of the process improvements identified through ATK's VSM approach reduced the number of product moves and other redundant processes, limiting exposure and reducing the risk of anomalies during manufacturing. For example, in one area a segment was previously moved 47 times during manufacturing; the ATK teams were able to reduce those moves to seven, saving labor costs and improving reliability. Another lean manufacturing change involved eliminating some of NASA's requirements for redundant inspections by incorporating ultrasound technology in place of X-ray and other inspection tools. NASA approved all of ATK's recommended VSM changes. "NASA support and encouragement through this process shows its commitment to building the Space Launch System more affordably to ensure a safe, reliable and?most important?sustainable program for this nation," said Precourt.

VSM improvements have been implemented throughout the manufacturing of Qualification Motor-1 (QM-1). Four segments have now been cast, and ATK will start integration of the motor in the test stand next month in preparation for a ground test in spring 2013.

In July, ATK was awarded one of four contracts to help reduce risk in the development of a new booster system for the Space Launch System. The ATK Integrated Booster Static Test consists of a ground test of an advanced booster design featuring advanced, high-performance propellant; a low-cost, lightweight composite rocket motor case; and an innovative and more affordable nozzle.

FMI: www.atk.com