Karen I. Emm

On-console operator for all phases of launch pad refurbishment, Falcon 9 vehicle and ground system day of launch checkouts, static fire, launch, and scrub operations. Developed automation to support test and operation of new launch pad hardware as well as continuous improvement of existing launch automation for efficiency, minimization of risk, and reduction of console controller load. Responsible for reviewing test failures/hardware health alarms and working closely with hardware responsible engineer and technicians to troubleshoot systems and verify safe configuration for launch. Authored procedures for safing and testing of high pressure fluid systems.

Quality Engineer Responsibilities: Conducted internal AS9100 audits to validate that ULA is effectively implementing their quality policy and drove corrective actions when gaps were found. Acted as Quality Material Review Board member to document nonconformances and vet resolution actions. Oversaw launch site corrective action board and human error prevention program - elevating events of concern to site/program leadership while aiding in determination of root cause and corrective actions. Performed close out review of all launch site documentation to validate completion or resolution of all procedures, nonconformance documents, photo and test requirements, and data observation reports. Reviewed changes in planning to ensure compliance with engineering drawings, mission specific test requirements, and company standards. System Safety Responsibilities: Coordinated waivers and tailoring of 91-710 requirements for fluid & structural GSE and facility design. Primary console communicator ensuring safety of personnel during launch preparations. Assessed Flight Caution Area maps and coordinated with Range Safety to minimize impact to ULA operations. Developed launch site process documentation for Atlas and Vulcan FAA License Applications.

Supported nonconformance review and final paperwork closeout for 33 rocket launch and recovery missions encompassing consultation for all Cape products areas. Performed root cause analysis and drove corrective actions for Falcon 9 first stage refurbishment process to initiate design and process changes, create vehicle acceptance criteria and standard repairs, clarify inspections, incorporate tribal knowledge into procedures, reduce workmanship errors, and eliminate processes escapes from build. Audited first stage refurbishment campaigns to evaluate the need for static fire, verify completion of maintenance actions required due to previous repairs, confirm R&R’d components vetted with appropriate levels of testing, and identify inappropriate floor usage of standard rework. Owned containment of hardware due to build escapes and newly identified hardware conditions from reuse. Trained quality inspectors and launch engineers in the processing of nonconformance documents.

Dispositioned manufacturing nonconformances on completed aircraft by researching engineering drawings and process specifications, coordinating with engineers, mechanics, and customers, and writing detailed work instructions. Worked repairs for metal and composite aero-structural components, exterior paints and finishes, interior installations, error codes generated during flight test, and various internal systems and sub-assemblies. Identified/tracked maintenance required prior to flight to help generate 737 MAX removal from storage plans. Gained experience with MRB, delivery operations, airplane storage, and interior certification.

Analyzed the performance of a MATLAB based satellite scheduling tool to ensure proper scheduling capability, retraced requirement gaps and managed requirements and linkages in DOORS for the creation of a program wide scheduling tool, contributed to the modification of a desktop 3D printer for high temperature material test coupons, and determined material ordering needs and charges for an additive manufacturing team. Gained experience with mission analysis, requirements tracking, and additive manufacturing processes.

Established a pull-system for a rotating parts cell by simulating production to determine Kanbans/running rules, reducing amount of work-in-progress, conducting time studies to establish standard work, gaining operator buy-in through training and simulation, and creating a WIP tracker, takt tracker, cross training board, and tooling Kanban . Project resulted in $1.6 million inventory reduction and direct labor hour savings of $400,000 yearly. Composed floor layout plan allowing for addition of 3 new machines. Created organized oiling system across shop to reduce operator downtime. Gained experience with lean principles, Six Sigma, 5S, and AutoCAD.

- Modernized R&M model for early-stage program to reflect changes in LCN, nomenclature, parts selection, reliability data, and MTTR to ensure system requirements are met. Conducted Mean Time to Repair (MTTR) analysis using CAD models, source control drawings, and maintenance manuals. Completed a Failure Modes Effects and Criticality Analysis (FMECA) on an intern-designed piece of support equipment. Gained experience with reliability predictions, Functional Block Diagrams, Reliability Block Diagrams, MTTR, and FMECA.