ATK [ATK] and NASA made progress in manufacturing the first ground test motor while ATK created cost-saving process upgrades for developing the solid rocket booster for the space agency’s Space Launch System, according to an ATK statement.
Through its company-wide Value Stream Mapping (VSM) process, ATK enabled employees to identify inefficient processes, procedures and requirements to help reach the target condition. Through this process, ATK identified more than 400 NASA-approved changes and improvements.
Many of the process improvements identified through ATK’s VSM approach reduced the number of product moves and other redundant processes, limiting exposure and reducing the risk of anomalies during manufacturing. ATK said it identified a segment that was previously moved 47 times during manufacturing and reduced the number of moves to seven, saving labor costs and improving reliability.
Another lean manufacturing change involved eliminating some of NASA’s requirements for redundant inspections by incorporating ultrasound technology in place of X-ray and other inspection tools. NASA approved all of ATK’s recommended VSM changes.
“NASA support and encouragement through this process shows its commitment to building the Space Launch System more affordably to ensure a safe, reliable, and—most important—sustainable program for this nation,” Charlie Precourt, general manager and vice president of ATK’s space launch division, said in a statement.
VSM improvements have been implemented throughout the manufacturing of Qualification Motor-1 (QM-1). Four segments have now been cast and ATK will start integration of the motor in the test stand next month in preparation for a ground test in the spring of 2013.
“We’re narrowing in on probably the May or June timeframe,” Fred Brasfield, vice president of ATK’s next-generation booster program, said in an interview recently. “We have some technical gates we have to get through over the course of the winter and early spring to get to that test.”
ATK in July was awarded one of four contracts to help reduce the risk in the development of a new booster system for SLS. The ATK Integrated Booster Static Test consists of a ground test of an advanced booster design featuring advanced, high-performance propellant; a low-cost, lightweight composite rocket motor case and an innovative, and more affordable, nozzle.