Applications of Failure and Anomaly Analysis for Space Systems

Space missions are inherently high-risk and expensive. The space environment is harsh, making space system design and manufacture difficult. By studying past failures/anomalies (F/A), measures may be adopted in the concept and design mission phases to prevent reoccurrences. This could potentially save missions from premature failure and extend useful-life. The F/As considered were studied by means of Failure Review Boards (FRB), F/A Review documents, NASA Lessons Learned, engineering handbooks, and science and engineering seminars. The project was meant to serve as an unbiased review of F/A root causes and as an educational resource for those interested in Applied Physics and Astronautical Engineering. Four major commonalities were identified through studies of the Joint Polar Satellite System (JPSS) and many other space systems reviewed for comparison. The common root causes include 1) Written Procedures and Training, 2) Electrical Grounding and Conductance Design, 3) Material Incompatibility, and 4) Process Induced Contamination Including Foreign Object Debris (FOD). Publicly available examples for each root cause category are explored and presented as a case study in how F/A analysis can be applied to improve the success rate of space systems. The findings from this research validated results from similar internal reviews. Additionally, we have proposed general preventative actions for each case study which could benefit future space missions. By developing a strong understanding of various F/As, space systems may be designed more robustly, and requirements for manufacture and operational performance written more effectively. For the designers of next generation space systems, the results of this project present an opportunity for accelerated success and avoidance of pitfalls by cognizant analysis and root cause investigation.