A Conversation With: Orion Management Team

In this issue, the USA Update talks to the leaders of USA’s Orion Team – Lloyd Gregg, Mark Thomas and Ray Reed – about the company’s role in supporting the Crew Exploration Vehicle (CEV) program. Gregg is the acting program manager of the CEV Office and director of Assembly, Integration and Ground Processing (AI&P) for the Orion Program Office. Thomas is the director of the USA Integrated Product Team and Systems Engineering Integration Team (IPT/SEIT) Support, and Ray Reed is the director of Flight Software and CEV Avionics Integration Laboratory (CAIL) for USA.

UPDATE: What will be the role of Orion in the Constellation Program?

GREGG: The Orion will be the next human-rated space vehicle that will return astronauts to the moon and on to Mars. The Orion vehicle consists of four primary modules. The Crew Module (CM) in which the astronauts and cargo will be transported, housing life support, avionics and thermal protection systems. The Service Module (SM) houses the systems for propulsion, electrical power and fluids storage. The Spacecraft Adapter (SA) will serve as the structural transition between the CEV and the launch vehicle, and the Launch Abort System (LAS), on top of the vehicle, is designed to pull the CM and the astronauts to safety in the event of an emergency.

It does look similar to the Apollo Command Module and SM, but it will have avionics and other systems utilizing today’s proven technology, which is grounded in over 40 years of space flight experience.

UPDATE: What were the key aspects of the Lockheed Martin proposal that helped that team win the Orion contract?

THOMAS: First, NASA’s feedback was that Lockheed Martin’s proposal was superior in the technical approach. In particular, they were impressed with numerous technical enhancements, concepts for avionics and software. The design also incorporates proven operations approaches and innovative technologies with integrated operational considerations.

Additional factors were Lockheed Martin’s safety and health plan, management approach, cost and past performance. NASA had high praise for the team’s methodology in Phase 1 of the CEV process – the design development period that began in July 2005 to perform concept refinement, trade studies, analyses of requirements and preliminary design options.

NASA also felt that the proposed concepts for avionics and software development were sound, effective and realistic. Additionally, they believed the proposed approach adequately minimized both schedule and technical risks.

NASA told Lockheed Martin that they believed the design of the spacecraft and innovative technologies in their proposal would provide efficiencies, reducing overall life cycle costs.

UPDATE: The awarding of the Orion contact to the Lockheed Martin team was a significant milestone for the Constellation Program. How did USA contribute to the Lockheed Martin CEV Contract capture effort?

REED: We first learned how to be an excellent subcontractor and demonstrated to Lockheed Martin how our core competencies fit into their overall strategy. Our core competencies include skills developed while working on the Cockpit Avionics Upgrade project, using modern tools and processes as well as the legacy Shuttle skills. We developed strong relationships with our Lockheed Martin counterparts and brought a wealth of human space flight experience and a knowledgebase built on supporting integrated product teams, ground operations, mission operations, the NASA customer, and flight software that are required for space exploration. We also brought a strong willingness to think outside of the box and propose innovative approaches to the design and concept of operations for Orion, while never forgetting or compromising safety.

UPDATE: With the Lockheed Martin team having work at many locations across the United States, what changes will there be to activity at current USA sites or at additional locations?

GREGG: In awarding the CEV Contact, NASA announced that manufacturing and integration of the vehicle components will take place at contractor facilities across the country. Lockheed Martin will perform the majority of the Orion vehicle engineering work at the Johnson Space Center (JSC), with structures manufacturing at Michoud. USA will complete manufacturing, final assembly and integration of the vehicle at the Kennedy Space Center (KSC).

We obviously will be expanding the CEV organization beyond the few people we have now to fit the work of manufacturing, final assembly, and refurbishment in the Operations and Checkout (O&C) Building, and LAS processing in the Rotation Processing and Surge Facility (RPSF) here at KSC, as well as flight software and CAIL development at JSC. The associated changes to infrastructure and facility modifications will precede some of this work. We also will have people on temporary duty in Denver supporting the Lockheed Martin design teams.

Ultimately, I expect as our USA team completes final assembly, integration and testing of the Orion, they will hand the spacecraft off to our USA vehicle processing counterparts who will then complete tasks, such as preflight processing, checkout and launch of the vehicle.

UPDATE: How will the Orion program provide opportunities for USA employees?

THOMAS: This contract indicates that Lockheed Martin and NASA have reviewed USA’s performance over the past 10 years and feel we are ready to take on expanded roles in support of spaceflight and exploration.

The CEV work represents many nontraditional roles for our company. We are involved in the design process through Integrated Product Teams that will enhance and streamline the efficiency and operability of the system in the future.

Also, as we mentioned earlier, USA will be involved in assembly of the CEV at KSC. We will have a major role in developing flight software and the CAIL with this work continuing through 2013 or 2014. Additionally, I expect USA to maintain a superior position to remain as NASA’s Operations Contractor on the Constellation Program.

UPDATE: What type of work will be performed in the AI&P area?

GREGG: One example of Lockheed Martin’s out of the box approach was the Florida Model concept. At a macro level, this involves use of existing NASA infrastructure coupled with cross utilization of USA’s skilled workforce. While the Orion primary structures will be built at Lockheed Martin’s Michoud Assembly Facility in Louisiana, for the first time on a human-rated vehicle, manufacturing of the CM and SM will be completed by the Lockheed Martin and USA workforce at the KSC’s O&C building. This is significant as it involves USA in the Original Equipment Manufacturer (OEM) processing role, similar to the work that Rockwell did on the Orbiters in Palmdale, Calif.

UPDATE: How is USA contributing to the Lockheed Martin partnership in the Integrated Product Team and Systems Engineering Integration Team (IPT/SEIT) Support arena?

THOMAS: Both teams are charged with making sure operational concerns are considered in the design to lower costs over the life of the program. We have about a two-and-a-half year window in which we can influence the designers before the Critical Design Review and hardware begins being built. After that, costs will increase considerably if changes are needed. So far, Lockheed Martin has been listening and is receptive to our recommended changes to the design. It’s been a very thorough and rigorous process to ensure the data backs up the recommendations, but in the end we will have a good vehicle.

The data and trade studies USA has used to make our inputs and recommendations have been based on our history in the human space flight business with the Space Shuttle and International Space Station (ISS) programs. We are coming forward with lessons from the past – how to do it and how not to do it – to make sure what we bring to the Lockheed Martin team is valid and the right thing to do.

UPDATE: Our contributions to the Lockheed Martin partnership also include the CAIL and flight software. What type of work will be performed in that area?

REED: USA will be supporting Lockheed Martin in designing, building and operating the CAIL. In particular, we are responsible for most of the simulation software. This will be similar to the Shuttle Avionics Integration Laboratory (SAIL) where USA tests Shuttle avionics and flight software upgrades for the Shuttle. Also at JSC, USA will support Lockheed Martin in developing flight software for the Orion project that will run onboard the CM and will be responsible for the hardware and software integration testing of most of the applications flight software.

Additionally, USA will be working with Lockheed Martin, Honeywell and other team members to establish an Engineering Development Lab (EDL). This was a major investment commitment by USA in support of the Lockheed Martin team. The EDL is a combination of capital investment and a major Internal Research and Development (IR&D) by Lockheed Martin, USA and the other team members. Our role is the setup and operation of the EDL and continued development of simulators, flight software and avionics tools for the betterment of the Constellation program.

UPDATE: What will it take for USA to succeed on the Orion team?

REED: USA’s performance both on our existing Shuttle and ISS contracts, as well as our new contracts, will determine how much additional scope we obtain. We have an excellent relationship developed with Lockheed Martin and need to continue growing this base. Our performance in demonstrating our proposed concepts, such as seamless resource sharing among contracts, ability to work in our prime contractors systems, and maintaining a streamlined work process, will be a significant strength as we look to the future. Knowledge of the new systems gained working on Constellation projects will be key as USA looks to future potential operations contracts opportunities.

The Orion will play a key role in providing a sustained human presence beyond low-Earth orbit to explore and continue our nation’s leadership in space flight. We’re proud that USA will be playing such an important role in making this happen.

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