A Return to Innovative Engineering Design, Critical Thinking and Systems Engineering

I believe we are racing a critical time where innovative engineering design is of paramount importance to the success or Our aerospace industry, However, the very qualities and attributes necessary for enhancing, educating, and mentoring a creative spirit are in decline in important areas. The importance of creativity and innovation in this country was emphasized by a special edition of the Harvard Business Review OnPoint entitled: "The Creative Company" [1] which compiled a series of past and present articles on the subject of creativity and innovation and stressed its importance to our national economy. There is also a recognition or a lack of engineering, critical thinking and problem-solving skills in our education systems and a trend toward trying to enhance those skills by developing K-12 educational programs such as "Project Lead the Way", "Science for All Americans", Benchmarks 2061", etc. [2,3,4]. In addition, with respect to spacecraft development, we have a growing need for young to mid-level engineers with appropriate experience and skills in spacecraft design, development, analysis, testing, and systems engineering. As the Director of Engineering at NASA's Johnson Space Center, I realized that sustaining engineering support of an "operational" human spacecraft such as the Space Shuttle is decidedly different than engineering design and development skills necessary for designing a "new" spacecraft such as the Crew Exploration Vehicle of the Constellation Program. We learned a very important lesson post Columbia in that the Space Shuttle is truly an "experimental" and not an "operational" vehicle and the strict adherence to developed "rules and processes" and "chains of command" of an inherently bureaucratic organizational structure will not protect us from a host of "known unknowns" let alone "unknown unknowns" [5]. There are no strict rules, processes, or procedures for understanding anomalous results of an experiment, anomalies with an experimental spacecraft like Shuttle, or in the conceptual design of a spacecraft. Engineering design is as much an "art" as it is a science. The critical thinking skills necessary to uncover lurking problems in an experimental design and creatively develop solutions are some of the same skills necessary to design a new spacecraft. Thus, I believe engineers unfamiliar with or removed from design and development need time to transition and develop the required skill set to be effective spacecraft designers. I believe the creative process necessary in design can be enhanced and even taught as early as grades K-12 and should continue to be nurtured and developed at the university level and beyond. I am going to present a strategy for developing learning teams to address complex multidisciplinary problems and to creatively develop solutions to those problems rapidly at minimal cost. I will frame a real problem, the development of on-orbit thermal protection system repair of the Space Shuttle, and step through the series of skills necessary to enhance the creative process. The case study I Will illustrate is based on a real project, the R&D Reinforced Carbon-Carbon (RCC) Repair Team's development of on-orbit repair concepts for damaged Space Shuttle RCC nose cap and/or leading edges.