from the dryer-lint-can-be-deadly dept.
Hugh Pickens writes "Dan Elliott reports that a piece of cloth inadvertently left in the fuel line during the manufacturing process may be the reason for the botched delivery to orbit of a military communications satellite that hasn't reached its planned orbit since it was launched in August. The Air Force Space Command and the contractor, Lockheed Martin, have devised a work-around plan using the remaining propulsion systems — reaction engine assemblies and electric Hall Current Thrusters drawing off of onboard fuel—to slowly raise the perigee of the Advanced Extremely High Frequency satellite until it reaches its intended orbit 22,300 miles over the Earth in October, but the GAO says that the $12.9 billion satellite system incurred at least $250 million in extra costs and a two-year delay because of quality problems due to poor workmanship, undocumented and untested manufacturing processes, poor control of those processes and materials and failure to prevent contamination, poor part design, design complexity, and an inattention to manufacturing risks. John Pike of Globalsecurity.org, which monitors defense issues, says the two-year delay is a bigger problem than the extra expense. 'You've got a lot of other things depending on the launch,' says Pike, including ground-based weapons."
No hardware designer should be allowed to produce any piece of hardware
until three software guys have signed off for it.
-- Andy Tanenbaum