SPACE RELIABILITY TECHNOLOGY: A HISTORICAL PERSPECTIVE.

This paper first discusses the earliest US space flight attempts and some of the reasons for their low success record. Then it examines the lessons learned which fed into the Thor-Able-Star and Delta launch vehicles, followed by the ICBM family. Improvements in design, materials, fabrication, workmanship, contamination control, testing, and management are discussed. The first major breakthrough in more formal reliability efforts, which occurred in the man-rating process for manned space flight, is examined. Special efforts to foster motivation are described. Introduction of reliability prediction to the design process in Apollo is presented. Growth of the failure mode and effects and criticality analysis techniques are shown, together with the growth of hazard analysis techniques are shown, together with the growth of hazard analyses via fault tree techniques. The identification of critical items, coupled with tender loving care (TLC) handling, hardware pedigree, exhaustive analysis of failed critical components to prevent recurrences, EEE part selection and application, use of clean rooms, improved NDE techniques, are all examined and their contribution evaluated. Factoring of lessons-learned into the Space Shuttle planning efforts is discussed.