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APO-1104REVISION ANational Aeronautics andSpace AdministrationRELEASE DATE: OCTOBER 14, 2011ARES PROJECTS OFFICEKNOWLEDGE MANAGEMENT REPORTApproved for Public Release; Distribution is UnlimitedThe electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 2 of 266REVISION AND HISTORY Baseline09/23/11ARevision A (incorporates minor edits andcombination of some related KIs)10/14/11DescriptionNOTE: Updates to this document, as released by numbered changes (Change XXX), areidentified by a black bar on the right margin.The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 3 of 266TABLE OF CONTENTSPARAGRAPH1.0PAGEINTRODUCTION . 221.1 PURPOSE . 241.2 SCOPE . 241.3 BACKGROUND . 252.0PROCESS AND EXPECTATIONS . 272.1 OVERALL APPROACH. 272.1.1Knowledge Capture Team Roles and Responsibilities . 292.1.2Distilling Team Roles and Responsibilities . 322.2 NORMS USED . 362.3 WORKSHOP RULES OF ENGAGEMENT. 362.4 CATEGORIES USED . 372.4.1Anchor Categories . 372.4.2Alternate Categories . 372.5 LENGTH OF EFFORT. 372.6 SUGGESTED IMPROVEMENTS TO THE KC AND DISTILLING PROCESS . 383.0KNOWLEDGE CAPTURE RESULTS . 403.1 OVERVIEW OF LESSONS LEARNED RECEIVED AND PROCESSED . 403.2 KEY THEMES . 403.2.1Leadership and Discipline . 403.2.2Plan Ahead . 413.2.3Communication . 423.2.4Establish Strong CM and DM Functions . 433.2.5Design and Analysis Integration . 443.2.6Experience . 453.2.7End Product . 463.2.8Budget and Schedule . 473.2.9Training . 48The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 4 of 2663.2.10 Cautions When Using Heritage Hardware and Ground Support Equipment (GSE). 494.0KNOWLEDGE ITEMS AND ACTIONS . 504.1 ANALYSIS . 504.1.1Number of Design Analysis Cycles (DACs) . 504.1.2Critical Math Models Needed Early . 504.1.3DAC Planning . 514.1.4DACs Too Long in Duration . 514.1.5Track Changes to OML as Part of Ares Design Analysis Cycle (ADAC) LogBook . 524.1.6Trade Study Involvement . 524.1.7TEAMS Tool Issue . 534.1.8Stacking Alignment Analysis . 534.1.9Evaluate Cost vs. Benefit for Failure Analysis and Tests . 534.1.10 Link Failure Analysis with Test for Validation. 544.1.11 Organization of Integrated Analyses . 544.1.12 More Robust System for Late Aborts. 554.1.13 Loss of Crew (LOC) and Loss of Mission (LOM) Analysis Integration . 554.1.14 Abort Environments Table . 554.1.15 Fault Management (FM) and Health Management (HM) Database . 564.1.16 Invest in Software Tools. 564.1.17 Priority of System Analyses . 574.1.18 Integrated Structural Model Requirements . 574.1.19 Structural Analysis Methodology . 574.1.20 Support Software Toolsets . 584.1.21 Integrated Analysis Roles . 584.1.22 Photogrammetry and Laser Scanning. 594.1.23 Model and Analysis Technical Interchange Meetings (TIMs) . 594.2 AVIONICS DESIGN . 604.2.1Sensor Procurement Was Confusing . 604.2.2Schedule Delay Due to Wait for Avionics Components . 60The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 5 of 2664.2.3Avionics Modeling . 614.2.4Controllers Design . 614.2.5Developmental Flight Instrument (DFI) Definition . 624.2.6Design Communication in Avionics . 624.2.7Structural Failure Case Recommendations . 634.2.8System Performance Models . 634.2.9Abort Condition Definition . 634.2.10 Support Abort Triggers Development . 644.2.11 Communication in the Area of Avionics and Software . 654.2.12 Operational Design Life . 654.2.13 Pre-Coordination of Electronic, Electrical, and Electromagnetic (EEE) Parts . 664.3 AVIONICS – SOFTWARE . 664.3.1Independent Software Test and Evaluation . 664.3.2Develop a Uniform Code and Methodology . 664.3.3Lack of Fault Management (FM) Analysis of Fault Detection, Diagnostics, andResponse (FDDR) Design. 674.3.4Establish Vehicle Time as Global Positioning System (GPS) Time . 674.3.5Automation and Roles and Responsibilities Never Defined . 674.3.6Software Test Article Requirements . 684.3.7Integrated Hardware and Software Reviews . 684.4 AVIONICS TEST . 684.4.1Hardware in the Loop (HWIL) and Prototyping . 684.4.2Stand-Alone Non-Real-Time Systems . 694.4.3Early Involvement of Test and Evaluation (T&E) Team . 694.4.4Use Similar Plans and Processes . 704.4.5Integrated Test Data Analysis Capability . 704.4.6Test Facilities Utilizing Same Process Would Be Beneficial . 704.4.7Supporting Avionics Integration . 714.4.8Software and Hardware Development . 714.4.9Algorithm Test Environments . 724.5 BUDGET AND SCHEDULE . 72The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 6 of 2664.5.1Budget Issues Beyond Control of the Project . 724.5.2Address Budget Inflexibility . 734.5.3Unfunded Infrastructure . 734.5.4Overoptimistic Planning Is Risky. 734.5.5Usability of Schedules . 744.5.6Schedule Tools, Staffing, and Processes Issues . 764.5.7Sequence of Planning for Scheduling . 764.5.8Resource Phasing . 774.5.9Cost Reporting for Affordability . 784.5.10 Cost Reporting Tools. 784.5.11 Establish Budget, Schedule, EVM Standards . 794.5.12 Establish EVM Training . 804.5.13 Establish Improved Work Authorization Process . 814.5.14 Resources for Training and Tools . 814.5.15 Unrecoverable Cost and Schedule Baselines . 814.6 PROGRAM AND IT SECURITY . 824.6.1Information Technology (IT) Security Improvement, Training, and Feedback 824.6.2Discipline and Personal Accountability for IT Security . 834.6.3Clarify IT and SBU Procedures. 834.6.4Data Security Requirements for Prime Contractors . 844.6.5Improve Process for Controlled Information Shared Between Centers . 844.6.6IT Tool Selection and Standards . 854.7 COMPUTER-AIDED DESIGN (CAD) . 854.7.1Develop CAD Standard Early to Avoid Impacts to the Release Process . 854.7.2Layout Drawings as the Design Baseline . 864.7.3Drawing Release Schedule Interdependencies . 864.7.4Establishing CAD Libraries . 874.7.5Integrated Vehicle Ground Vibration Test (IVGVT) Test Facility Top-DownDesign and Drawing Process . 874.8 CONFIGURATION MANAGEMENT (CM) . 884.8.1Confusion with Board Approval Process . 88The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 7 of 2664.8.2Improve Change Process Screening . 884.8.3Improve Change Process Turnaround Time . 894.8.4Drawing Configuration Control . 894.8.5Software Configuration Management Process Not Followed . 904.8.6Reaction Control System (RCS) CM and Data Management (DM) Approach 904.8.7Documents Written by Committee . 904.8.8Establish CM Discipline . 914.8.9CM Define Core Processes and Standards for Programs/Projects . 914.8.10 CM Define Configuration and Interface Control Process and Needs . 924.8.11 CM Define Change Process and Responsibilities . 924.8.12 CM Tool Selection and Final Decision Authority. 934.8.13 CM Training . 934.8.14 CM Standardized Directive Language . 944.8.15 CM Need for Status and Accounting . 944.8.16 Baseline Documents from Top Down Early in Program . 954.9 CULTURE . 954.9.1Lack of Face-to-Face Discussions on Technical Topics . 954.9.2Fear of Failure . 964.9.3Engineering Directorate (ED)/Project Interface . 964.9.4Kennedy Space Center (KSC) Organizational Structure Confusing andCooperation Lacking. 964.9.5Communication Barriers Due To Various Locations . 964.9.6Lack of Structural Analysts to Support IVGVT . 974.9.7Teambuilding Activities Were Exceptional . 974.9.8Multi-Level Communication Forums . 974.9.9Pre-Coordination with Prime Contractor is Beneficial . 984.9.10 Branch Chief Rules and Governance Understanding . 984.9.11 Too Many Processes . 984.9.12 Build Trust Between NASA Team and Production Contractor . 994.10 DATA MANAGEMENT (DM) . 99The electronic version is the official approved document.Verify this is the correct version before use.

Ares ProjectsRevision: Revision ARelease Date: October 14, 2011Title: Ares Projects Knowledge Management ReportDocument No: APO-1104Page: 8 of 2664.10.1 Design and Data Management System (DDMS) Limitations in Drawing Release. 994.10.2 Pro/E Synchronization Between Centers . 994.10.3 DDMS Collaboration Issues . 1004.10.4 Design Data Difficult for Integrated Vehicle Ground Vibration Test (IVGVT) toAcquire . 1004.10.5 Duplication of Effort on Documentation Tasks . 1004.10.6 Engineering Release Plan . 1014.10.7 Establish DM Discipline . 1014.10.8 DM Training . 1024.10.9 DM Data Requirements Process. 1024.10.10 DM Tool Selection and Final Decision Authority . 1034.10.11 DM Plan . 1034.10.12 DM Early (First) Data Protocols . 1034.10.13 DM Steering and User Group . 1044.10.14 Standardization of Software Tools Across Levels, Projects, and Programs . 1044.10.15 Improvements to the Data Exchange Process . 1054.10.16 Data Access . 1054.10.17 Sensitive But Unclassified (SBU) Classification . 1064.10.18 Standardized Document Formats vs. Native Data. 1074.10.19 Process, Standards, and Guideline Creation . 1074.10.20 Low-Level Design Requirements . 1084.10.21 Retrieving Audio Decision Data . 1084.10.22 Records Management Plan Complete Early . 1084.10.23 Information Manager (IM) “Certification” Process . 1084.10.24 Customer Feedback . 1094.10.25 Information Management Process Improvements . 1094.11 ENGINEERING PLANNING . 1104.11.1 Communication of Design Reviews . 1104.11.2 Role of Engineering Management . 1104.11.3 Poorly Defined Systems Engineering Roles and Responsibilities . 110The electronic version is the official approved document.Verify this is the correct version before use.