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Unethical Decisions - The Causes of the Space Shuttle Challenger Disaster Roger Boisjoly — Transcript

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  1. 0:45I'm eating I don't know whether this is
  2. 0:49because professor black shares lunches
  3. 0:52are you a little longer than usual this
  4. 0:53quarter but we'll be starting from 335
  5. 0:57from now on the questions related to
  6. 1:03ethics are being raised in a number of
  7. 1:06arenas today in education we see this in
  8. 1:09the proposal for the liberal education
  9. 1:13of the University of Minnesota where
  10. 1:15there are strong recommendations for
  11. 1:17courses and ethics we see this in the
  12. 1:19requirements of the Accreditation Board
  13. 1:21for Engineering and Technology where is
  14. 1:24a strong push for engineering ethics
  15. 1:28courses for engineers and it's fine to
  16. 1:32do this in what we sometimes call an
  17. 1:34academic manner in terms of reading
  18. 1:36about ethical problems and ethical
  19. 1:38issues and and decisions made on ethics
  20. 1:41and either from a textbook or from a
  21. 1:43faculty member but today we'll have a
  22. 1:45living example of an issue in
  23. 1:48engineering ethics and the person that
  24. 1:50played a key role in in in a very
  25. 1:53important manner it's been said that the
  26. 1:56engineering advances often as a result
  27. 1:59of failures that we learn from the
  28. 2:02analysis of failures of systems what one
  29. 2:05might do in the future and what one must
  30. 2:08do in the future and that's fine and and
  31. 2:11there's a certain more than grain of
  32. 2:13truth to that perhaps but one thing is
  33. 2:15to learn from failures that one could
  34. 2:17not predict before the failure occurred
  35. 2:19it's another thing when people were
  36. 2:21predicting a particular failure and then
  37. 2:23it occurs and and that latter issue is
  38. 2:25the one which we'll hear about today and
  39. 2:27it's truly a an ethical issue which will
  40. 2:30go down in the history of engineering in
  41. 2:32the history of the u.s. the failure that
  42. 2:35led to the disaster of the of the space
  43. 2:39shuttle Challenger is one that was well
  44. 2:40known to everybody here today it's an
  45. 2:44issue that raised problems related to
  46. 2:47engineering decisions versus what were
  47. 2:49called some extent management decisions
  48. 2:51brings rise to questions of the need for
  49. 2:54having technical leadership at
  50. 2:57proper levels and industry and that
  51. 2:59technical leadership making decisions on
  52. 3:01technical grounds as well the speaker
  53. 3:04today is one who has been called with
  54. 3:07the good reason a whistleblower and has
  55. 3:12suffered all of the the bad as well as
  56. 3:15some of the good that occurs to
  57. 3:17whistleblowers as you'll hear about
  58. 3:19today I think it's a rare opportunity
  59. 3:21for us to hear the firsthand about the
  60. 3:24key issues related not only to what has
  61. 3:28become a very tragic incident but also
  62. 3:30key issues related to what engineers
  63. 3:32must do and consider when practicing in
  64. 3:36industry Roger Beaujolais is a graduate
  65. 3:39of what is now the University of Lowell
  66. 3:42he received an engineering degree there
  67. 3:43in 1960 he worked for a number of
  68. 3:47companies generally related to aerospace
  69. 3:51industry from July 1980 he started to
  70. 3:56work for Morton Thiokol in Utah he
  71. 3:59worked there through of course the
  72. 4:00incident on the Challenger which was in
  73. 4:02January 86 and left the company later on
  74. 4:06in 1986 he's been giving lectures at
  75. 4:09some other educational institutions I
  76. 4:12heard him a few years ago speak at the
  77. 4:14American Society of Mechanical Engineers
  78. 4:15meeting I'm sure you'll all be impressed
  79. 4:18with the knowledge he'll in part today
  80. 4:21and the sincerity in which he'll deliver
  81. 4:23mr. Poli
  82. 4:38oh I can come on lightboxes off there we
  83. 4:52go okay good afternoon what I'm going to
  84. 4:57do is define to you the circumstances
  85. 5:00leading to the challenge of disaster and
  86. 5:02give you a factual chronology of what
  87. 5:05happened that led to the decision-making
  88. 5:08process before I start I'd like to give
  89. 5:11you somewhat of a familiar familiar
  90. 5:14ization process here well looking at
  91. 5:16here is that what we call the stack on
  92. 5:17the shuttle the solid rocket boosters
  93. 5:19the external tank and the orbiter itself
  94. 5:21and I'm going to be primarily focusing
  95. 5:26on the solid rocket booster phase the
  96. 5:30booster is actually made up of four
  97. 5:32segments that are transported to Cape
  98. 5:34Canaveral and assembled ready for launch
  99. 5:36we're looking at the forward section
  100. 5:39forward Center the App Center in the aft
  101. 5:43section containing the nozzle itself the
  102. 5:45reason I show you this is because I want
  103. 5:47to point out a full booster and show you
  104. 5:48this is the joint that failed and this
  105. 5:51is the configuration of that particular
  106. 5:53joint I have a full-size set of pictures
  107. 5:56of that in the moment another joint that
  108. 5:58I will be discussing is part of the
  109. 6:00escalation of the problem is this nozzle
  110. 6:02joint that looks like so and again I
  111. 6:04have a full-size graph of that that I
  112. 6:06want to show you what really started
  113. 6:12with like what the concerns was the fact
  114. 6:16that when we assemble this this filled
  115. 6:19joint you can see we have vacuum putty
  116. 6:23located between the two interfaces on
  117. 6:26either side of this joint the joint is
  118. 6:28configured with a clevis and a tang the
  119. 6:32tank fits into the clevis with two
  120. 6:33o-rings we refer to the first o-ring
  121. 6:36that the hot gas had the potential of
  122. 6:38reaching through this path right here as
  123. 6:40their primary or ring seal and then the
  124. 6:43redundant secondary seal behind it was
  125. 6:46the flight rate man rating of this
  126. 6:50basically this was our backup seals
  127. 6:52should anything ever occur in hot gas
  128. 6:54get past this primary seal now the gas
  129. 6:57that this system was to protect against
  130. 6:59was approximately 5700 degrees
  131. 7:01Fahrenheit and it was never intended to
  132. 7:03have any holes in this party it was
  133. 7:05never intended for this gas to ever come
  134. 7:07down and penetrate and even reach a seal
  135. 7:09but unfortunately the mechanism of
  136. 7:12assembly caused and trapped air to occur
  137. 7:14and occasionally and quite frequently in
  138. 7:17fact we'd get bore holes in this putty
  139. 7:19which would then provide a path during
  140. 7:22ignition for the hot gas to come down
  141. 7:23and attack the o-ring seals just to show
  142. 7:27you well I guess not on a more vivid
  143. 7:29detail I had a full scale model here but
  144. 7:31I think I will forego that the joints
  145. 7:34were actually put together like I said
  146. 7:36Tang in clevis and pinned in a hundred
  147. 7:39and seventy seven locations these pens
  148. 7:41one inch diameter actually carried the
  149. 7:43structural load as the internal pressure
  150. 7:45was generated as you can see here this
  151. 7:48is a propellant outline and there's
  152. 7:50actually a hole down the centerline of
  153. 7:52the motor so large in fact that you
  154. 7:54could actually stoop down and walk down
  155. 7:55the full length of this motor these
  156. 7:57components were twelve foot in diameter
  157. 7:59and contained 1.1 million pounds of
  158. 8:03propellant when they were fully
  159. 8:04assembled ready for flight at the Cape
  160. 8:06the problem really started to escalate
  161. 8:09in January of 1985 in January of 1985 I
  162. 8:13was at the Cape and when the boosters
  163. 8:16were recovered for reuse and
  164. 8:18refurbishment and disassembled at the
  165. 8:21Cape I inspected them and I found two
  166. 8:23failed joints of the character that I
  167. 8:25just showed you had massive leaks in
  168. 8:27them we had compromised the primary seal
  169. 8:30and two filled joints in fact they were
  170. 8:32compromised so bad that in one joint
  171. 8:34we actually had eighty degrees of
  172. 8:37blackened grease between these two seals
  173. 8:39which indicated the products of
  174. 8:40combustion had actually blown by this
  175. 8:42first primary seal and fortunately were
  176. 8:45actually stopped by the secondary seal
  177. 8:47one joint had 80 degrees arc length and
  178. 8:49the other joint had 110 degrees arc
  179. 8:51length was postulated after this launch
  180. 8:53that these seals had a temperature of 53
  181. 8:55degrees Fahrenheit well in by March
  182. 8:58early late March late February early
  183. 9:02March of 1985
  184. 9:03I had brought this information back and
  185. 9:06one of my colleagues former supervisor
  186. 9:08in fact had devised what we referred to
  187. 9:09as a resiliency test to actually test
  188. 9:12the capability of these seals to perform
  189. 9:14in an environment that we had not
  190. 9:17previously tested for namely alloy the
  191. 9:19normal launch temperature we found out
  192. 9:22for these pulmonary Orange resiliency
  193. 9:24tests that we were in severe problem
  194. 9:28area at 50 degrees Fahrenheit the seals
  195. 9:31had a distinct problem with them at that
  196. 9:33temperature we presented this
  197. 9:35information to engineering management if
  198. 9:37I call but they felt it was just too
  199. 9:39sensitive to release to anybody and so
  200. 9:41they just kept it secret the only people
  201. 9:44that really know about it was the
  202. 9:45individuals who had actually worked and
  203. 9:47knew about the tests and and were privy
  204. 9:49to the results well and I will I will
  205. 9:53give you this data later on in the
  206. 9:55presentation so you know precisely what
  207. 9:57the data encompassed in June of 1985 the
  208. 10:01problem escalated once again we opened
  209. 10:05up a a nozzle joint this time and the
  210. 10:09nozzle joint is made up of a joint that
  211. 10:11looks like so this is what we call the
  212. 10:14nozzle fixed housing and a nozzle cone
  213. 10:17actually lays across the exit like so
  214. 10:19and so what we have here is a piece of
  215. 10:23metal that supports the gimballed nozzle
  216. 10:26that actually is attached to the F
  217. 10:27closure dome and the metal parts are
  218. 10:30heavily insulated because of the
  219. 10:32turbulence of the gas in this area and
  220. 10:34again we find a gap between the
  221. 10:36insulation which was filled with vacuum
  222. 10:37putty again the primary seal would be in
  223. 10:40this location the first seal designated
  224. 10:42as the primary is that is the seal that
  225. 10:44would first be attacked by hot gas
  226. 10:46should it ever occur now in this joint
  227. 10:48we have a different characteristic in
  228. 10:50that we have a very very safe secondary
  229. 10:52seal which is a face seal around the
  230. 10:55corner it's actually squeezed between
  231. 10:56two massive pieces of metal this
  232. 10:58represents almost the full-scale
  233. 11:00cross-section of what we're looking at
  234. 11:01we have a hundred one in an eighth inch
  235. 11:03diameter bolts that actually clamp this
  236. 11:05face together
  237. 11:06now what I'm about to show you when we
  238. 11:09is what we found when we opened up this
  239. 11:11joint in June of 1985 from an actual
  240. 11:15flight that occurred in April
  241. 11:17this particular segment was actually
  242. 11:18sent back to psych all in Utah with the
  243. 11:21nozzle intact on this particular
  244. 11:23assembly and we just assembled it at
  245. 11:25Utah cause it was much easier to do it
  246. 11:27that way back at our plant now what I'm
  247. 11:29about to show you is the condition of
  248. 11:31the seal that actually came out of that
  249. 11:34joint and I'd like to point out to
  250. 11:36people this is not a cartoon this is an
  251. 11:39actual photographic cross-sections of
  252. 11:42the seal that will remove from that
  253. 11:43joint and as you can see the seal had
  254. 11:46three heat-affected notches in it from
  255. 11:48the hot gas each of these cross-section
  256. 11:51refers to a notch as shown in the plan
  257. 11:54view now what we're looking at side view
  258. 11:56what we're looking at here is this
  259. 11:58highlighted the dark highlighted outline
  260. 12:00is the amount of seal material that
  261. 12:02remained as opposed to the round
  262. 12:05circular cross-section that should have
  263. 12:06been there and if you look at this worse
  264. 12:08cross-section I would estimate that
  265. 12:11somewhere between 75 and 80 percent of
  266. 12:12the cross section has been vaporized by
  267. 12:14the hot gas we postulated that this
  268. 12:17cross section in this seal had never
  269. 12:20sealed for the full two minutes of
  270. 12:22booster flight and so we really had a
  271. 12:25brand-new ballgame here because if
  272. 12:27whatever happened to this joint and we
  273. 12:30come up with several postulations as to
  274. 12:32what it might have been but after all we
  275. 12:34don't have crystal balls but whatever
  276. 12:36happened to this joint if it should
  277. 12:37happen to a filled joint then all bets
  278. 12:39are off because the filled joint might
  279. 12:41fail because both of those seals bore
  280. 12:43seals on the same surface and it's not
  281. 12:46difficult to predict that whatever
  282. 12:48happened to one could happen to the next
  283. 12:50one in line now at the same time this
  284. 12:52was going on in this joint
  285. 12:53the secondary seal around the corner
  286. 12:55that very safe seal that I spoke to you
  287. 12:57about was also eroded 30 mm of an inch
  288. 13:01and so we really had a new problem on
  289. 13:05our hands and another miss Ann Ennis
  290. 13:08well this was so serious that for the
  291. 13:11next flight right in this review we had
  292. 13:14to go down and present a complete status
  293. 13:19of all the booster seals on the shuttle
  294. 13:21program to NASA at the Marshall Space
  295. 13:22Flight Center so we did this and because
  296. 13:25of the seriousness of this what we just
  297. 13:27found on this seal it was decided
  298. 13:30engineering management that they would
  299. 13:31now release the information that they
  300. 13:33had been keeping secret up to this time
  301. 13:34and they presented that information to
  302. 13:37NASA now everybody on the program knew
  303. 13:39about the seriousness of these seals and
  304. 13:42they're serious functional capabilities
  305. 13:45at 53 degrees Fahrenheit actually at 50
  306. 13:47because that was the whole limit we
  307. 13:49tested well as you can imagine I waited
  308. 13:52for some action to take place and I
  309. 13:53waited two four weeks and virtually
  310. 13:56nothing was done they had formed an
  311. 13:58unofficial task force team but virtually
  312. 14:00nothing was being done after two weeks
  313. 14:03of frustration with this activity I
  314. 14:05wrote a memo on a 31st of July 1985 to
  315. 14:10the vice president of engineering at
  316. 14:11Morton Thiokol and I'd like to give you
  317. 14:13a sense of that memo in quote one
  318. 14:16paragraph the memo ended by saying quote
  319. 14:19it is my honest and very real fear that
  320. 14:21if we do not take immediate action to
  321. 14:24dedicate a team to solve the problem
  322. 14:26with the field joints having a
  323. 14:27number-one priority then we stand in
  324. 14:29jeopardy of losing a flight along with
  325. 14:32all the launchpad facilities I also
  326. 14:34mentioned in that memo that we were
  327. 14:37going to experience a failure the
  328. 14:38highest order loss of human life on
  329. 14:41August 15th a seal task force team was
  330. 14:44officially formed I believe is the
  331. 14:46direct result of that memo although no
  332. 14:48one ever talked to me about that memo
  333. 14:51the Vice President engineering never
  334. 14:53wrote me a memo back or never talked to
  335. 14:55me about the contents of that memo but
  336. 14:57he published a memo officially forming
  337. 14:59this team which had five of us
  338. 15:02designated as full-time members out of
  339. 15:05approximately 2,500 people working on
  340. 15:06the program not all of whom were
  341. 15:08engineers of course unfortunately for us
  342. 15:10they were assigned to this team we
  343. 15:12received virtually no management support
  344. 15:14whatsoever the major production program
  345. 15:17dominated all available resources as we
  346. 15:20struggle to get changes tested and
  347. 15:25implemented in the program itself well
  348. 15:28on August 19th NASA headquarters was
  349. 15:30getting a little antsy so they asked for
  350. 15:31presentation from Morton Thiokol again
  351. 15:33on the status of the booster seals on
  352. 15:35the shuttle program and that's the
  353. 15:38management was assured by thiokol senior
  354. 15:40people that it was safe to continue fine
  355. 15:43well January 27th was the concluding
  356. 15:45major event that was in front of us
  357. 15:49prior to the challenge of disaster on
  358. 15:51that day we got a rather benign
  359. 15:52telephone call asking if we were
  360. 15:55concerned about the predicted overnight
  361. 15:56temperature low of 18 degrees Fahrenheit
  362. 15:59and of course being the only technical
  363. 16:02person that had seen the joints
  364. 16:03disassembled via before I bought went
  365. 16:05into orbit without any booster assist at
  366. 16:07all and very very concerned along with
  367. 16:09my colleagues we mustered up a group of
  368. 16:12engineers that were extremely concerned
  369. 16:13with what we were faced with we
  370. 16:16convinced thiokol engineering management
  371. 16:18and also the business side of the house
  372. 16:19on my dad that day that it was not safe
  373. 16:22to launch under these conditions based
  374. 16:24on our previous years experience and the
  375. 16:26experience during the year in the
  376. 16:28escalation of the problem we were asked
  377. 16:30by and we transmitted this informally to
  378. 16:33the Marshall Space Flight Center NASA
  379. 16:34Massa Marshall Space Flight Center we
  380. 16:36were asked to give a formal presentation
  381. 16:38that evening to express our concerns so
  382. 16:40a formal talk on was convened and we
  383. 16:43were at Morton Thiokol in Utah where we
  384. 16:46were gathered there were 14 of us there
  385. 16:49were a group at the Kennedy Space Center
  386. 16:50and then there was a group at the
  387. 16:52Marshall Space Flight Center which was a
  388. 16:54technical branch that had oversight for
  389. 16:55the shuttle solid rocket boosters
  390. 16:57we started our presentation and what I'd
  391. 17:00like to show you is a sampling or the
  392. 17:03view graphs that we presented that night
  393. 17:04and I'd like to point out to people that
  394. 17:07we had precisely about 45 minutes to
  395. 17:09present prepare this formal presentation
  396. 17:12and we as individuals went to our own
  397. 17:14offices and prepared prepared these view
  398. 17:16graphs and none of us knew what the
  399. 17:19other people were presenting except we
  400. 17:21saw it in real time but I hope that you
  401. 17:24understand after you see them that what
  402. 17:25we presented was enough information from
  403. 17:27an engineering standpoint to stop the
  404. 17:29flight what this was was a sheet in a
  405. 17:32cartoon that I had torn right out of an
  406. 17:34October 85 presentation to SAE that I
  407. 17:37gave to 130 technical experts in this
  408. 17:39nation concerning the sales in this
  409. 17:41joint in how they operate as I solicited
  410. 17:43help from their expert opinions so I had
  411. 17:47this at my fingertips so I included this
  412. 17:49I thought this would be another neat way
  413. 17:51to drive the point home once again what
  414. 17:53the problem was
  415. 17:54if you look at this top view with this
  416. 17:56centerline of the segment being here
  417. 17:58relative to this piece here you'll find
  418. 18:00that everything is as it should be when
  419. 18:03it's assembled you see how the o-rings
  420. 18:04are touching both sides of the surfaces
  421. 18:06that's how or ings are really supposed
  422. 18:08to work but you'll find in in the
  423. 18:11pressurized view down below with the
  424. 18:14same criteria this is the centerline
  425. 18:15relative to this view that as pressure
  426. 18:18is applied to this cylinder in the walls
  427. 18:20actually bulge out radially the joint
  428. 18:23doesn't deflect quite as far because it
  429. 18:25has a largest stiffness well the effect
  430. 18:27of that differential deflection is to
  431. 18:29cause this inboard clevis leg to deflect
  432. 18:32in towards the centerline of the motor
  433. 18:33at the same time that the Tang is
  434. 18:35deflecting outboard with the resulting
  435. 18:37effect that this gap opens tremendously
  436. 18:39on the order of 42 to 60 thousandths of
  437. 18:43an inch the 42 thousandths of an inch is
  438. 18:45a measured maximum number conducted in
  439. 18:4712 tests with hydraulic oil as we had
  440. 18:50measured over the period of time this is
  441. 18:52my best estimate of 60,000 switch may be
  442. 18:55a practical upper limit since we had
  443. 18:57only run 12 tests and I wasn't about to
  444. 18:59stand up and say that we had screened
  445. 19:01out the maximum at that point in time
  446. 19:02and so this was my best estimate now
  447. 19:05when I presented this to seal experts in
  448. 19:07San Diego at sae nobody said a word and
  449. 19:11I know why they didn't say a word
  450. 19:12because these are more than an order of
  451. 19:13magnitude beyond the accepted industrial
  452. 19:16standards for the uses of o-ring design
  453. 19:18these should be on the order of a
  454. 19:20thousand so it's two thousandths of an
  455. 19:22inch
  456. 19:23and we're talking 42 to 60 thousandths
  457. 19:25of an inch in a pressurized condition
  458. 19:27with an o-ring of that size now the
  459. 19:29problem is exacerbated even further
  460. 19:32because you'll see that the secondary
  461. 19:34o-ring has lifted off its seal see
  462. 19:37that's the problem with this joint when
  463. 19:40the joint opens that much this small
  464. 19:42diameter seal with with the 20,000th
  465. 19:44minimum squeeze on it does not have the
  466. 19:47margin to allow it to stay seated on its
  467. 19:50mating surface and so this is a
  468. 19:52misapplication of o-ring technology and
  469. 19:55if you want to look at what happened to
  470. 19:56challenge it just picture both o-ring
  471. 19:58seals looking like the secondary seal
  472. 20:01position both o-rings will lift it off
  473. 20:03in hot gas won't roaring by eating the
  474. 20:05seals that will lift
  475. 20:06off alive as it went out the case
  476. 20:08continued a slow leak until it reached
  477. 20:10about 50 seconds then it started to flow
  478. 20:12more rapidly and the trace on the
  479. 20:14pressure transducer at the head end
  480. 20:16showed the the the pressure drop falling
  481. 20:18at the same time the hole was growing at
  482. 20:2073 seconds the hole is analytically
  483. 20:23predicted to be about 25 inches in
  484. 20:25diameter when they found the pieces it
  485. 20:27was about 25 inches in diameter I had
  486. 20:32also taken this right out of the August
  487. 20:3519th presentation though
  488. 20:36NASA headquarters I had prepared this
  489. 20:38chart for that presentation although I
  490. 20:40didn't present it at that time you can
  491. 20:42see way back in August my primary
  492. 20:45concern was at the field units that had
  493. 20:47the highest concern the erosion
  494. 20:49penetration of the primary si requires a
  495. 20:51reliable secondary seal for pressure
  496. 20:53integrity and I've broken it down into
  497. 20:55two conditions ignition transient and
  498. 20:58steady-state in a 0 to 600 millisecond
  499. 21:01region is the time it takes to go from
  500. 21:03zero pressure to a thousand for PS I
  501. 21:07broke that down into three regimes 0 to
  502. 21:09170 milliseconds we have a high
  503. 21:12probability of having a secondary co in
  504. 21:16other words the secondary seal will be
  505. 21:17contacting like the primary seal because
  506. 21:19we have really not experienced any joint
  507. 21:22rotation yet because nothing is really
  508. 21:24happening it's just starting to be
  509. 21:26pressurized in the 170 to 330
  510. 21:29millisecond region we have somewhat a
  511. 21:31reduced probability because now motion
  512. 21:33is is starting and then 330 to 600 we
  513. 21:36have a high probability that we might
  514. 21:38not have secondary seal capability now
  515. 21:41how did we know this well we had done
  516. 21:44bench testing that actually showed us
  517. 21:45this and bench testing also showed us
  518. 21:47that the initial phase of 100 and 0 to
  519. 21:50170 milliseconds was safe and if we
  520. 21:53should ever penetrate the seal primary
  521. 21:56seal after the initial ignition
  522. 21:58transient we had a high probability that
  523. 22:01we would have no secondary seal
  524. 22:02capability because it would be lifted
  525. 22:04off and so what we were talking about
  526. 22:06here is timing function if you'll find
  527. 22:09this referred to later on as timing
  528. 22:11function and
  529. 22:15this was nothing new they had seen this
  530. 22:18before but this was just kind of
  531. 22:19reinforce what we had already presented
  532. 22:22to them what this chart was was a chart
  533. 22:26made up and you see it's hand printed we
  534. 22:28didn't have the time to get it typed up
  535. 22:29I just hand printed this so you have to
  536. 22:31excuse some of the the words and you can
  537. 22:33see I just stuck things in as
  538. 22:36appropriate I did this specifically for
  539. 22:39Challenger that other chart had nothing
  540. 22:41to do a challenger that was a general
  541. 22:42chart and the program itself and you'll
  542. 22:45notice that I had no mention of
  543. 22:46temperature in the other chart I was
  544. 22:47afraid of these joints even at room
  545. 22:49temperature in the middle of summer
  546. 22:50because that joint was simply a lousy
  547. 22:53design a temperature lower than the
  548. 22:56current database results in changing the
  549. 22:57primary no ring sealing timing function
  550. 23:00those are the three zones that I
  551. 23:01described previously that was my fear
  552. 23:03that we'd slide from that first safe
  553. 23:05zone to one of those two other zones and
  554. 23:08heaven forbid the last zone nearing 330
  555. 23:12milliseconds this is the January 85
  556. 23:15launch designated as the 15th white
  557. 23:17where we had 80 and 110 degrees of arc
  558. 23:19length of black and grease luring
  559. 23:22squeeze would result in would be at the
  560. 23:25result of lower temperature I'd actually
  561. 23:26run a calculation that day which showed
  562. 23:28the cross section of the O ring to
  563. 23:29shrink by one thousandth of an inch not
  564. 23:31very much but we didn't have very much
  565. 23:33to spare and it's in a wrong direction
  566. 23:34higher o range short hardness that
  567. 23:37material gets just like a brick when it
  568. 23:40freezes we were just slightly above the
  569. 23:42glass transition temperature which is
  570. 23:44defined as the temperature of an
  571. 23:46elastomer at which all the way the
  572. 23:47spaces disappear and it is now like a
  573. 23:49piece of metal thicker grease viscosity
  574. 23:53not the best wording in the world but
  575. 23:54what I'm referring to is the
  576. 23:56slipperiness or the quality of the
  577. 23:57grease to allow the o-ring to slide into
  578. 23:59position it would impede that someone
  579. 24:02higher or ring pressure actuation time
  580. 24:04is a result of lower temperature than we
  581. 24:07had experienced previously now the
  582. 24:09bottom two bullets sum up the whole
  583. 24:12discussion that evening in the whole
  584. 24:15fear if the actuation time increases the
  585. 24:17threshold of secondary seal
  586. 24:19pressurization capability is approached
  587. 24:21that was what we were really afraid of
  588. 24:23if the threshold is reached then it's
  589. 24:26really a jump ball
  590. 24:27we might not be able to seal these
  591. 24:29joints we were not talking about these
  592. 24:31joints sealing once the seals are
  593. 24:33sealing and working and being attacked
  594. 24:35by hot gas we were talking that night
  595. 24:37about them even functioning as being
  596. 24:40able to function as seals before the hot
  597. 24:41gas ate them alive this is the infamous
  598. 24:45data that we obtained in the February
  599. 24:46March timeframe in 1985 and as you can
  600. 24:48see by the data when we ran these tests
  601. 24:51now let me first explain what we
  602. 24:53actually did we actually took an o-ring
  603. 24:55between two steel plates and and we
  604. 24:59squeezed down to two steel plates to
  605. 25:02actually represent this action right
  606. 25:05here on the on the actual joint and what
  607. 25:10we were doing is squeezing it down
  608. 25:12squeezing an o-ring down let me just
  609. 25:15actually make it perfectly clear by
  610. 25:17putting an o-ring seal in there we
  611. 25:18actually squeezing the o-ring down 40
  612. 25:20thousands of an inch and then removing
  613. 25:2330 thousandths of that squeeze so we
  614. 25:26should have had a residual squeeze of
  615. 25:27ten thousandths of an inch and measuring
  616. 25:30and you know by optical means and white
  617. 25:32means whether or not the o-ring still
  618. 25:35maintained contact with both metal parts
  619. 25:37well we did that at a hundred degrees
  620. 25:39Fahrenheit and we found that at a
  621. 25:42hundred degrees the o-ring maintained
  622. 25:45contact with the metal parts we did it
  623. 25:48in 75 degrees Fahrenheit and we found
  624. 25:50that it separated for 2.4 seconds and at
  625. 25:5350 degrees the same tests produced the
  626. 25:56results of separation for an excess of
  627. 25:5810 minutes we start measuring after 10
  628. 26:00minutes because it was ridiculous to to
  629. 26:02proceed with with further measurement
  630. 26:04because 10 minutes and 2.4 seconds
  631. 26:07compared to 200 milliseconds actually I
  632. 26:10designated it as a hundred and 70
  633. 26:11milliseconds now that 170 milliseconds
  634. 26:14was my best estimate post-disaster
  635. 26:16testing was literally thousands of tests
  636. 26:18pointed to real number being 200
  637. 26:21milliseconds so I missed it by a few
  638. 26:23ticks if you can see that this also was
  639. 26:27a unconservative test but we had fixed
  640. 26:30machine settings at the time and this
  641. 26:32was only preliminary set of data we
  642. 26:34actually separated to inches a minute in
  643. 26:36the flight rate was 3.2 inch inches per
  644. 26:38minute so this was slightly
  645. 26:39unconservative
  646. 26:40but I I point to this and tell everybody
  647. 26:44that's in engineering I only need one
  648. 26:46piece of negative data to shut something
  649. 26:47down I can't necessarily say the same
  650. 26:50thing to go forward with a project but I
  651. 26:52only need one negative piece of data to
  652. 26:54shut something down that was a very bad
  653. 26:56piece of data to continue going forward
  654. 27:00with this program and yet and this is
  655. 27:03the data we presented and had in our
  656. 27:04possession that evening and I was asked
  657. 27:06during of course a telephone
  658. 27:07conversation to produce other data and
  659. 27:09how to share frustration from being
  660. 27:11badgered I basically blurted it out that
  661. 27:14I'm sorry I don't have anything other
  662. 27:15than what I presented because I've been
  663. 27:17trying to get other data since last
  664. 27:19October and in the system just would not
  665. 27:21allow me to get it and when I said that
  666. 27:23the general manager Bob Plant just about
  667. 27:25come out of his chair the conclusions
  668. 27:28and the next chart the recommendations
  669. 27:30chart were actually written and
  670. 27:31presented by the vice president
  671. 27:32engineering at Mullen cycle based on our
  672. 27:34input up to up to the meeting time the
  673. 27:38temperature of the o-ring is not the
  674. 27:39only parameter controlling buh-bye well
  675. 27:41absolutely that's a given statement
  676. 27:42because we had blow-by at various
  677. 27:44temperatures but the characteristic of
  678. 27:46the Bulova is the important thing to
  679. 27:47understand the January flight had blow
  680. 27:51by with an o-ring temperature about 53
  681. 27:53degrees we had for development motors
  682. 27:55with no blow by in the range of 47 to 52
  683. 27:58degrees but there's a caveat to that
  684. 27:59right away the development mortis had
  685. 28:02party packing which resulted in better
  686. 28:03performance now let me explain that to
  687. 28:05you there tested in a horizontal
  688. 28:06position and it's a very difficult
  689. 28:08assembly and so when they were assembled
  690. 28:10and they walked down the joint after
  691. 28:12assembling looked at the putty in the
  692. 28:13character of the joint from the inside
  693. 28:15they found that they were like little
  694. 28:16fall kennels volcanoes in the putty
  695. 28:18holes and they attributed that to the
  696. 28:21very difficult in severe assembly in the
  697. 28:23horizontal position and so they just
  698. 28:25slammed them shut with the handle of a
  699. 28:28broom for instance or shove some more
  700. 28:30putty in and tapped it shut so they
  701. 28:32didn't really represent what they had in
  702. 28:34flight but they and it was okay the
  703. 28:37rationale was okay up to that point but
  704. 28:39they should have investigated the flip
  705. 28:40side of that coin which was does it do
  706. 28:42the same thing when we assemble it
  707. 28:43vertically because they're assembled
  708. 28:46vertically at the Cape now when they
  709. 28:50finally got around to doing that it was
  710. 28:52in the middle
  711. 28:53part of 1985 middle to latter part in
  712. 28:561985 what do you think they found they
  713. 28:58found that when they assembled it
  714. 28:59vertically it also blew holes and putty
  715. 29:01so by not doing those tests early on in
  716. 29:04the program they essentially voided the
  717. 29:05development qualification testing
  718. 29:07relative to oring erosion due to heart
  719. 29:09gas impingement so we really couldn't
  720. 29:12use that data that night even though it
  721. 29:13was stated at about 50 degrees
  722. 29:15Fahrenheit we expect blow by the current
  723. 29:17it's a reasonable assumption we headed
  724. 29:19at 53 the year before well with
  725. 29:21inexperienced base we expect the
  726. 29:24temperature to be 29 degrees at 9:00
  727. 29:26a.m. and 38 degrees at 2 o'clock in the
  728. 29:29afternoon for lunchtime those were
  729. 29:31options that we were concerning that
  730. 29:33night we have no data other than
  731. 29:36temperature that would make these joints
  732. 29:39any different than anything else we have
  733. 29:41ever flown in fact from a geometry
  734. 29:42standpoint we presented that that
  735. 29:44evening but to keep it somewhat in hand
  736. 29:46here
  737. 29:46I don't present it anymore we add
  738. 29:48geometry joints that had better
  739. 29:50overhangs squeeze on them then most of
  740. 29:52the joints we had previously flown so we
  741. 29:54have a better set of joints from a
  742. 29:55geometry standpoint recommendations
  743. 29:58basically state don't fly it and if you
  744. 30:00have to fly it for heaven's sakes back
  745. 30:03out the conditions of ambient
  746. 30:04temperature and wind to produce a sealed
  747. 30:07temperature of no more than 53 degrees
  748. 30:10Fahrenheit and that basically was the
  749. 30:12end of our presentation it lasted about
  750. 30:14an hour as questions were batted back
  751. 30:17and forth and in discussion at times got
  752. 30:20very heated so we sat down and now it
  753. 30:24was management's turn our manager was
  754. 30:27asked by the project manager at the
  755. 30:30Kennedy Space Center who was actually a
  756. 30:31Marshall Space Flight Center in type for
  757. 30:34his launch decision and our project
  758. 30:38manager responded that he did not
  759. 30:40recommend launching based on the
  760. 30:42engineering presentation just made now
  761. 30:44pay attention that's the first no vote
  762. 30:46many of you probably don't even know
  763. 30:47that the original decision was made not
  764. 30:49to launch but it was and so that dispels
  765. 30:52all this garbage about we were too
  766. 30:56technical in our presentation and the
  767. 30:58managers didn't understand they
  768. 30:59understand fully they understood fully
  769. 31:01the original decision was made not to
  770. 31:03launch then Larry Malloy who was the man
  771. 31:05asking the questions asked his
  772. 31:06essentially his chief engineer at the
  773. 31:08Marshall Space Flight Center for his
  774. 31:09launch decision hey George Hardy
  775. 31:12responded that he did not he was
  776. 31:14appalled at the high calls
  777. 31:15recommendation but he would not
  778. 31:17recommend launching over the contractors
  779. 31:19objection that's the second no vote then
  780. 31:22Larry Malloy who was the man asking the
  781. 31:24questions went into a summary mode and
  782. 31:26that's when he made some of his famous
  783. 31:28comments about when do you want me to
  784. 31:31launch thiokol next April and this
  785. 31:34remember this was January and they had a
  786. 31:36very aggressive launch schedule that was
  787. 31:39George Hardy statement about being apart
  788. 31:41was the start of the pressure I know it
  789. 31:43because I felt that George Hardy was a
  790. 31:45highly respected individual in the
  791. 31:47program and worked for NASA for many
  792. 31:49many years and when George Hardy says
  793. 31:50he's appalled I'll tell you he damn well
  794. 31:52gets the attention or everybody
  795. 31:53listening and I felt the pressure and I
  796. 31:56felt the pressure about the comments
  797. 31:57from Irene Molloy and I was very very
  798. 32:00nervous about it he concluded with a
  799. 32:04statement that he was his opinion that
  800. 32:06the data we presented was inconclusive
  801. 32:07now think about that statement for a
  802. 32:09moment we're at this meeting Flight
  803. 32:11Readiness review meeting to prove that
  804. 32:12it's safe to launch his statement about
  805. 32:15our data being inconclusive actually
  806. 32:17violates
  807. 32:18NASA's long-standing conditions of
  808. 32:21forcing contractors and themselves to
  809. 32:22prove that it's safe to launch his
  810. 32:25statement about the data being
  811. 32:26inconclusive is actually an automatic
  812. 32:27default or no launch condition if you
  813. 32:29think about it so that's three no votes
  814. 32:31including man asking questions as soon
  815. 32:35as he gets finished speaking our program
  816. 32:37manager asked for five-minute offline
  817. 32:40carcass to reevaluate the data now it's
  818. 32:45the caucus that actually constitutes the
  819. 32:46unethical decision-making for him in my
  820. 32:48opinion because if they had done nothing
  821. 32:51except hang up the phone they'd have
  822. 32:53been great shape they claims the
  823. 32:55Presidential Commission I manages claim
  824. 32:57that they felt no pressure at all but I
  825. 32:58submit to you if they didn't feel any
  826. 33:00pressure why they asked for the caucus
  827. 33:01the decision had already been made not
  828. 33:03to launch so I know they felt the
  829. 33:05pressure because I felt the pressure and
  830. 33:06I was there they started to have a
  831. 33:09meeting amongst themselves because the
  832. 33:11first word spoken when the mute button
  833. 33:12button was pushed on mute was spoken by
  834. 33:15a general manager
  835. 33:16he said in a soft voice we have to make
  836. 33:18a management decision and I emphasize
  837. 33:20soft voice because he wasn't speaking to
  838. 33:22me he wasn't speaking of my colleagues
  839. 33:24on the other end of the table I was less
  840. 33:26than five feet away from them so I heard
  841. 33:28I heard every word spoken he was
  842. 33:30speaking to his other three senior
  843. 33:32executives who were all vice presidents
  844. 33:33three of which were gathered right
  845. 33:35around the table one of which was
  846. 33:36sitting up against the wall
  847. 33:38never did but the man against wall never
  848. 33:40did participate in anything except shook
  849. 33:42its head yesterday's gonna launch in the
  850. 33:44ultimate decision anyways they were
  851. 33:46trying and struggling trying to make a
  852. 33:49list on a piece of paper that would
  853. 33:51justify a decision to launch when my
  854. 33:53colleague Ani Thompson came from way
  855. 33:54down the other end of the table up place
  856. 33:56the pad of paper down and once again
  857. 33:58sketched out the joint with the
  858. 34:00explanation verbally why we should not
  859. 34:02attempt the launch under such adverse
  860. 34:04conditions Arnie was summarily ignored
  861. 34:06got the vilest looks you can ever ever
  862. 34:08ever imagine he went back to his place
  863. 34:11because he had no way of getting them
  864. 34:15engaged in conversation with him when he
  865. 34:18gave up and went back to his seat I
  866. 34:19grabbed eight-by-ten colour glossy
  867. 34:21photographs that showed the 1985 launch
  868. 34:26and the heart gasps buh-bye in the
  869. 34:28blackened condition between the seals I
  870. 34:31also had a comparative photograph of a
  871. 34:34room-temperature launch which showed the
  872. 34:36same type of blow-by but with a totally
  873. 34:38different characteristic it was gray
  874. 34:40sort of modelling splotchy in
  875. 34:42characteristic and it was like night and
  876. 34:44day between the two all you had to do to
  877. 34:46say to anybody a person on the street
  878. 34:48was that the color black is bad and
  879. 34:51tells you that you're in worse shape
  880. 34:52now which pick pick one that's in worse
  881. 34:54shape and a hundred times out of a
  882. 34:56hundred times they could pick the right
  883. 34:57photograph when I made that pitch to our
  884. 35:00managers they just did not want to hear
  885. 35:03it
  886. 35:03they didn't want to look at the
  887. 35:04photographs they didn't want me to talk
  888. 35:05to them they just Summerlee ignored me
  889. 35:07also I was told by my colleagues after
  890. 35:09the meeting that I was literally
  891. 35:11screaming at the managers to look at the
  892. 35:13photographs and not ignore what they
  893. 35:15were telling him namely that more hot
  894. 35:16gas blow-by occurred at a lower
  895. 35:18temperature but they didn't want to hear
  896. 35:19that and so I got the same works as
  897. 35:21Arnie and I went back to my seat also as
  898. 35:24they continue their discussion just
  899. 35:26before they took the vote poll Dave I
  900. 35:28sprint the vice-president senior vice
  901. 35:29president and general
  902. 35:30manager turn third vice president of
  903. 35:32engineering and said it said to him take
  904. 35:34off your engineering hat and put on your
  905. 35:36management hat
  906. 35:37real subtle threat huh well
  907. 35:40vice-president engineering capitulated
  908. 35:42unfortunately they took the vote poll
  909. 35:44shortly thereafter it was four votes to
  910. 35:47launch Presidential Commission asked
  911. 35:49them why they didn't pull us and the
  912. 35:52general manager said we already knew the
  913. 35:54position of the engineers and it was
  914. 35:56fruitless to pull them because we knew
  915. 35:58we would not be unanimous now see that's
  916. 36:00what they're supposed to do and if
  917. 36:02anybody is not unanimous that's a
  918. 36:04default when no launch but yet we
  919. 36:06weren't given the opportunity they were
  920. 36:08back on the telephone conversation told
  921. 36:11NASA that and they read from this list
  922. 36:13that they had generated told NASA that
  923. 36:14they wanted the launch but this was the
  924. 36:16new decision there was very little
  925. 36:18questioning no probing discussion NASA
  926. 36:20promptly accepted the decision telephone
  927. 36:23telecon was basically terminated now I
  928. 36:27was very angry when I left that room
  929. 36:28believe you if I had had a box of
  930. 36:30grenades that evening cycle would have
  931. 36:32been leveled this is the decision-making
  932. 36:36chart that they actually based their
  933. 36:39decision on now you ask yourself as I go
  934. 36:41down these statements one of the time if
  935. 36:43these are actual statements that support
  936. 36:46a decision to launch the calculations
  937. 36:49show that SRM 25 o-rings will be 20
  938. 36:51degrees colder than SRM 15 this is the
  939. 36:54Challenger Challenger will be 25 degrees
  940. 36:5620 degrees colder excuse me than the
  941. 36:58January 85 o-rings remember the name is
  942. 37:02temperature data not conclusive there's
  943. 37:05that word again
  944. 37:05not conclusive on predicting primary
  945. 37:08o-ring bull by the engineering
  946. 37:11assessment is that that is a why an
  947. 37:15outright bull face lie there was no
  948. 37:18engineering assessment that carcass the
  949. 37:20only two engineers who spoke were myself
  950. 37:22in Arnie Thompson and we were not
  951. 37:23allowed to be engaged in discussion and
  952. 37:25so that that is a absolute falsehood
  953. 37:29colder ol rings will have increased
  954. 37:31effective durometer in other words
  955. 37:33they'll be harder do you remember that
  956. 37:34on my chart is a reason for changing the
  957. 37:37timing function in the fear of launching
  958. 37:39harder o rings will take longer to see
  959. 37:41that's another way of saying timing
  960. 37:44function but this look makes it look
  961. 37:45like it's a positive attribute instead
  962. 37:47of a negative attribute more gas may
  963. 37:50pass the primary o-ring before the
  964. 37:52primary seal seats
  965. 37:53that's the magic wand trick you had 24
  966. 37:57successful voice and you just declare
  967. 37:58it's going to work it's going to see you
  968. 38:01can't do that people you we don't know
  969. 38:03what's going on inside those joints in
  970. 38:05real time the demonstrated sealing
  971. 38:07threshold is three times greater than a
  972. 38:0938 thousands of Rochin experience on a
  973. 38:11january flight that is a true statement
  974. 38:14but it does not apply
  975. 38:16we were not discussing oring erosion
  976. 38:19that night we were discussing if the
  977. 38:22seals would function first as seals
  978. 38:24before the hot gas ate him alive and
  979. 38:27then we had a comfortable three factor
  980. 38:31of safety of three on margin we had
  981. 38:32tested many subscale tests and that was
  982. 38:35a real number but it didn't apply that
  983. 38:37night we were afraid that the seals
  984. 38:39weren't even function as seals first if
  985. 38:42the primary seal does not seat the
  986. 38:44secondary will the magic wand trick
  987. 38:46again I don't know how you can do that
  988. 38:48pressure will get that a secondary seal
  989. 38:51before the metal parts rotate I don't
  990. 38:53know how they knew that I'd it was the
  991. 38:56closest person and Ronny was the second
  992. 38:58closest person all those joints and we
  993. 38:59certainly didn't know that there had
  994. 39:01never been never been one test dynamic
  995. 39:05test run on pressure temperature or
  996. 39:07deflection running these motors why
  997. 39:09because in order to run those tests you
  998. 39:11have to drill holes in a case and drill
  999. 39:13hole in a joint you void 1 million
  1000. 39:16dollars worth of hardware for flight
  1001. 39:18that's why I didn't run tests but I'll
  1002. 39:20show you after the Challenger disaster
  1003. 39:22they drilled holes like you can't
  1004. 39:25believe in a joint they took flight
  1005. 39:27hardware out of the stream like it was
  1006. 39:29popcorn but yet before the disaster we
  1007. 39:33could never get that information the
  1008. 39:35o-ring pressure leak check places the
  1009. 39:37secondary seal in the output position
  1010. 39:39which minimizes sealing time that
  1011. 39:41doesn't say anything it's just filler
  1012. 39:43that's a fact of physics if I put
  1013. 39:45pressure on one side of an o-ring it
  1014. 39:47will move to the opposite side of the
  1015. 39:48groove and it will do it a thousand
  1016. 39:49times out of a thousand times ragazza
  1017. 39:51what the temperature is unless it's
  1018. 39:52frozen solid to the deck it doesn't say
  1019. 39:55anything it's like pushing a cable with
  1020. 39:56casters it's going
  1021. 39:57move as opposed to being grounded its
  1022. 40:00just filler morton-thiokol recommends at
  1023. 40:03the launch proceeded on the 28th now
  1024. 40:05does anybody in the audience see
  1025. 40:07anything after that statement I sure
  1026. 40:09don't see the CEO Morton Thiokol was
  1027. 40:12late as the spring of 1988 said in an
  1028. 40:14interview with Businessweek magazine as
  1029. 40:16he was still trying to protect his
  1030. 40:18corporate hind side that Morton Thiokol
  1031. 40:20never agreed to launch at the
  1032. 40:22temperature at the time of launch and I
  1033. 40:24maintain to you oh yes they did right
  1034. 40:26there it doesn't there's no caveat
  1035. 40:30there's no exceptions there's nothing on
  1036. 40:32that that says they can't launch and
  1037. 40:33quite frankly if it had dropped to 20
  1038. 40:35below zero NASA what this chart has the
  1039. 40:38authority to launch the last poet
  1040. 40:41actually contradicts the first bullet
  1041. 40:43the Challenger will not be significantly
  1042. 40:46different from the January 85 launch it
  1043. 40:48just said it'd be 20 degrees colder and
  1044. 40:50we had met I thought we had made a
  1045. 40:52pretty good case for the increments from
  1046. 40:54a hundred down to 75 down to 50 degrees
  1047. 40:57Fahrenheit the severity and how they
  1048. 40:59overran responded and that it was very
  1049. 41:01very important in those increments that
  1050. 41:04at the law we got the more serious
  1051. 41:05difficulty we were going to have well
  1052. 41:08when this was this chart was finished
  1053. 41:10NASA asked for a signed copy of this
  1054. 41:12chart as you can see Joakim insta who's
  1055. 41:15the guy our program manager signed it
  1056. 41:17and it was faxed down this is the
  1057. 41:19ultimate cya piece of paper in the
  1058. 41:20program because NASA knew that they
  1059. 41:24needed this signed to protect themselves
  1060. 41:26I have to tell you ladies and gentlemen
  1061. 41:28that the only temperature that anybody
  1062. 41:29knew about in that program including me
  1063. 41:31that night and up to that night and
  1064. 41:33since that night was 40 degrees
  1065. 41:36Fahrenheit period 40 degrees Fahrenheit
  1066. 41:39I wasn't willing to launch neither when
  1067. 41:43my colleagues at 40 degrees Fahrenheit
  1068. 41:44but that is the lowest temperature that
  1069. 41:46any of us on a program even knew about
  1070. 41:48and so they did violate launched with
  1071. 41:52criteria al McDonald told Larry Malloy
  1072. 41:54at the Kennedy Space Center he would
  1073. 41:56hate to be the one that had to stand up
  1074. 41:58in front of a board of inquiry and
  1075. 41:59explain why he launched below the
  1076. 42:01specification temperature of 40 degrees
  1077. 42:03Fahrenheit but he was ignored at that
  1078. 42:05point in time also well I had made up my
  1079. 42:07mind not to watch the launch next day
  1080. 42:09because I was very very
  1081. 42:11afraid that what we were predicting was
  1082. 42:13going to occur but one of the colleagues
  1083. 42:16that was in the room that night had a
  1084. 42:18daughter that I call that day who had
  1085. 42:20never seen the launch and he had another
  1086. 42:21daughter that worked at that call and I
  1087. 42:23knew them as family friends and so I sat
  1088. 42:25in with him as he coaxed me to come in
  1089. 42:27and watch well as the vehicle ignited
  1090. 42:30and cleared the lunch tower I whispered
  1091. 42:32to Bob that we just dodged a bullet
  1092. 42:35because we were told by the ballas
  1093. 42:37ditions the people the engineers who are
  1094. 42:39experts on how propellants burn and how
  1095. 42:41they work and from past experience that
  1096. 42:43they had they told us if we had so much
  1097. 42:45as a tiny pinhole in the case it would
  1098. 42:47blow up on the pad right at ignition
  1099. 42:49well when that didn't happen of course I
  1100. 42:51felt wow we're home free at 60 seconds
  1101. 42:55in the launch he would speed back to me
  1102. 42:57that he had just completed a prayer of
  1103. 42:58thanks for a successful launch thirteen
  1104. 43:01seconds later we both saw the horror of
  1105. 43:03destruction along with our colleagues in
  1106. 43:04a room as the vehicle exploded and there
  1107. 43:07was no mistake in our minds that it had
  1108. 43:09exploded because it was way premature in
  1109. 43:12the separation it should have gone 120
  1110. 43:14seconds and as typical engineers we all
  1111. 43:17got acronym and it's out every time
  1112. 43:18there's the launch and we time it was a
  1113. 43:19stopwatch I always do that
  1114. 43:21and it was 73 seconds when it let go but
  1115. 43:24strangely enough right after the
  1116. 43:25explosion occurred and I was very angry
  1117. 43:29even even knowing this our boost is
  1118. 43:31actually flew out of the explosion still
  1119. 43:33thrusting so it wasn't us but I was
  1120. 43:36still mad in hell because that they had
  1121. 43:38just listened and not launched that
  1122. 43:39sequence of events would not have
  1123. 43:41occurred whatever the cause at that
  1124. 43:43point in time well one of the managers
  1125. 43:46was in that room actually the man that
  1126. 43:48said nothing that night except shook his
  1127. 43:50head yes to vote to launch he went out
  1128. 43:53of that room like he was shot out of a
  1129. 43:54cannon because I think he realized what
  1130. 43:58serious trouble the program was in at
  1131. 44:00that point in time because of what had
  1132. 44:02transpired the evening before well any
  1133. 44:04Johnny Thompson and myself were actually
  1134. 44:07placed on a fairly investigation team in
  1135. 44:09prompt order and sent to the Marshall
  1136. 44:11Space Flight Center in Alabama and what
  1137. 44:14I saw there shocked me and actually made
  1138. 44:17me very very angry and disgusted NASA
  1139. 44:20management at the center was diligently
  1140. 44:22attempting to find a condition other
  1141. 44:23than
  1142. 44:24that caused a disaster I think they knew
  1143. 44:27the seriousness of what they had done
  1144. 44:29and they were trying to actually pin
  1145. 44:32this disaster in something else they had
  1146. 44:34actually closed out photographs of the
  1147. 44:36assembly and and they claimed that there
  1148. 44:39was a twisted o-ring and I swore up and
  1149. 44:41down to them that I just tried a piece
  1150. 44:42of o-ring and twisted it actually put it
  1151. 44:45on put it on a desk you know had about a
  1152. 44:48yard length of it was secretary of white
  1153. 44:50out tape and twisted it full 360 degrees
  1154. 44:54three times and I left it on my desk in
  1155. 44:57it unfold and the white out tape was in
  1156. 44:59a line which says that the stored energy
  1157. 45:02and o-ring was sufficient to avoid a
  1158. 45:04twist in it now it was just on a desktop
  1159. 45:07imagine how I would act and greased on a
  1160. 45:09greased surface would even be dipped
  1161. 45:10more difficult I did with him and argued
  1162. 45:13with him and argued with him that that
  1163. 45:14couldn't possibly happen and what they
  1164. 45:15were seeing was a track that somebody
  1165. 45:18had caused by just wiping inadvertently
  1166. 45:20wiping the surface with a glove or hand
  1167. 45:22they actually sent a team of experts out
  1168. 45:25to if I call in spent two weeks trying
  1169. 45:27to take a photograph over twisted o-ring
  1170. 45:29in a joint of course they couldn't do it
  1171. 45:31after two weeks they came back and said
  1172. 45:33wow I guess you were right
  1173. 45:34well even more important than that we're
  1174. 45:39on a fairly investigation team we never
  1175. 45:41showed this information for a week to
  1176. 45:45ten days later they had actually known
  1177. 45:48within 24 hours of launch what actually
  1178. 45:50caused a disaster but those on a fairly
  1179. 45:52investigation team whenever made privy
  1180. 45:54to it they had 16 millimeter film of it
  1181. 45:56you see this arrow right here that
  1182. 45:59points that is black smoke this is the F
  1183. 46:02joint right here see the black smoke
  1184. 46:04coming out of the F joint this is right
  1185. 46:05at the ignition this is at point six
  1186. 46:08eight seconds this is a slight delay
  1187. 46:11because there was postulated there may
  1188. 46:13have been some frozen water in the joint
  1189. 46:14and it delayed it slightly but that's
  1190. 46:16pretty close to at the beginning
  1191. 46:18ignition if you'd taken that the white
  1192. 46:20time they knew that and they had never
  1193. 46:23told us so we're on a fairly
  1194. 46:24investigation team as they chased us
  1195. 46:25down blind alley after blind alley after
  1196. 46:27blind alley well
  1197. 46:32after al McDonald had made the
  1198. 46:35presidential commission aware that the
  1199. 46:36telecon took place they scheduled a the
  1200. 46:38presidential commission scheduled a
  1201. 46:40closed-door hearing at the Kennedy Space
  1202. 46:41Center on the 14th of February 1986 we
  1203. 46:46were instructed by the company attorneys
  1204. 46:47to go that meeting and answer all
  1205. 46:49questions yes to know and volunteer
  1206. 46:51nothing can you imagine how much
  1207. 46:54information they would have really found
  1208. 46:55out if we had done that well I I wasn't
  1209. 46:57willing to do that and I bared all I was
  1210. 46:59pardon me the first to testify Arnie was
  1211. 47:02second and he basically verified
  1212. 47:04everything I said and add a few words
  1213. 47:05himself then now McDonnell gave his
  1214. 47:07version as he was at the Kennedy Space
  1215. 47:09Center that night what the Commission
  1216. 47:11members heard was so shocking to them
  1217. 47:13that they asked us to all leave close
  1218. 47:14the door
  1219. 47:15placed a call directly to President
  1220. 47:17Reagan and informed him of what had
  1221. 47:19happened they were so afraid that
  1222. 47:21because of what they just heard would
  1223. 47:22never ever last to the end of the day
  1224. 47:24before the press got it that they didn't
  1225. 47:27want the president broadsided and so
  1226. 47:28they made the call one of the aides to
  1227. 47:30the Commission told us this well five
  1228. 47:32days later I was being interviewed by
  1229. 47:34another Commission member and I handed a
  1230. 47:36packet of my activity reports and memos
  1231. 47:40to him as in answer to one of his
  1232. 47:42questions and a company attorney present
  1233. 47:44literally almost fell off his chair I
  1234. 47:47realized at that point in time that I
  1235. 47:49had truly not endeared myself with
  1236. 47:50company management
  1237. 47:52because my memos actually stopped their
  1238. 47:57testimony cold in its tracks and clearly
  1239. 48:00proved that this problem had been around
  1240. 48:02way before that telecon meeting and I
  1241. 48:05had the documented evidence that I had
  1242. 48:07handed over to him to prove it and so
  1243. 48:09from that point on management had a very
  1244. 48:12very difficult time in testifying with a
  1245. 48:14series of half-truths and from that
  1246. 48:17point on the focus of the investigation
  1247. 48:19was not only on the technical failure of
  1248. 48:24the joint but on a management managerial
  1249. 48:26failure of the organization on February
  1250. 48:2825th we got to tell our story in public
  1251. 48:31and I fell into further disfavor by
  1252. 48:34directly rebutting our general managers
  1253. 48:36testimony just before me where he
  1254. 48:37claimed that the engineering position at
  1255. 48:39the talk on meeting that evening was not
  1256. 48:41unanimous and that was simply not true
  1257. 48:43every body in the room that evening was
  1258. 48:46there for the sole and specific purpose
  1259. 48:47of stopping the launch even the general
  1260. 48:49manager believe it or not he anticipated
  1261. 48:52that it would be a highly politicized or
  1262. 48:54potentially criticized problem but he
  1263. 48:58knew what we were striving for before
  1264. 49:01the meeting even started so if he didn't
  1265. 49:03support it he sure as hell didn't in
  1266. 49:05voice voice his opinion against anything
  1267. 49:07and so the default is that everybody
  1268. 49:09that was in that room they remained
  1269. 49:11silent was there for the sole purpose of
  1270. 49:13supporting the launch that's why they
  1271. 49:14were there in all actuality well after
  1272. 49:18my testimony I was off the failure
  1273. 49:20investigation team immediately sent back
  1274. 49:21to Utah and at while I was being told in
  1275. 49:24March that I was a major participant in
  1276. 49:26the redesign I was felt very strange
  1277. 49:28because I was it seemed like I was being
  1278. 49:30isolated from the program I was given
  1279. 49:32technical input but never invited to
  1280. 49:34meetings never knew when they occurred
  1281. 49:35never knew who attended I was told by
  1282. 49:37the grapevine that my technical input
  1283. 49:39was changed from time to time and I had
  1284. 49:42no input essentially I was essentially
  1285. 49:44being isolated it took me about six
  1286. 49:45weeks in real time to really understand
  1287. 49:47that this was happening well in May al
  1288. 49:52McDonnell and I would call back to the
  1289. 49:53Presidential Commission we were asked
  1290. 49:55point-blank about our job assignments
  1291. 49:56and when I answered the question with
  1292. 49:59the fact that I was being isolated from
  1293. 50:00the program and that al and said that he
  1294. 50:03had 30 people that were reporting to him
  1295. 50:05originally now
  1296. 50:07we're not reporting him anymore and he
  1297. 50:08was now reporting to one of them
  1298. 50:10Presidential Commission got very very
  1299. 50:12angry because they said we were being
  1300. 50:14punished for honesty and our testimony
  1301. 50:16well the company took out a lot of flack
  1302. 50:20about this because the Presidential
  1303. 50:22Commission actually at least the
  1304. 50:23closed-door hearings and made it public
  1305. 50:25and thiokol got beat up very severely in
  1306. 50:27the press by the press the Presidential
  1307. 50:30Commission and the Congress of the
  1308. 50:31United States it got so bad that our
  1309. 50:34colleagues at the plant were now blaming
  1310. 50:37us for all of that cause problems
  1311. 50:40we started referred to ourselves at the
  1312. 50:42five lepers there were five of us that
  1313. 50:44testified in one degree or another and
  1314. 50:45we were being ostracized by our
  1315. 50:47colleagues we tried to cause a
  1316. 50:51mitigation of the internal strife by
  1317. 50:52asking for a meeting with the CEO the
  1318. 50:55president of the aerospace division and
  1319. 50:57the person heading a shuttle program at
  1320. 50:58that time because the program was
  1321. 51:01actually coming down around their ears
  1322. 51:02and it was out of control because the
  1323. 51:03original people who were controlling the
  1324. 51:05program made the decision to launch was
  1325. 51:07still controlling the program if you can
  1326. 51:09believe that it was still in their
  1327. 51:10position the meeting unfortunately was
  1328. 51:13one-sided totally one-sided we bared our
  1329. 51:16souls to try and help the program in the
  1330. 51:18company and we were basically ostracized
  1331. 51:20and the CEO made it sound like that if
  1332. 51:23everything worked out okay all would be
  1333. 51:25forgiven and that was basically the tone
  1334. 51:29of the meeting that took place that
  1335. 51:30night well in June we were all called
  1336. 51:33back once again and this time to testify
  1337. 51:34in front of the presidential not
  1338. 51:39presidential but the house cyant House
  1339. 51:41Committee on science and technology when
  1340. 51:44we went back there it was really an a
  1341. 51:47bad experience for me extremely bad
  1342. 51:49experience for me during two days of
  1343. 51:51intensive preparations with attorneys
  1344. 51:53and PR people I and we in general but I
  1345. 51:57specifically were the victims of an
  1346. 51:59attempted PR people brainwashing as they
  1347. 52:02told us that the Congress the United
  1348. 52:04States the people on this committee we
  1349. 52:06were only interested in press coverage
  1350. 52:07and they really didn't give a damn about
  1351. 52:08Challenger how do you think you know
  1352. 52:11that made somebody like me feel it was
  1353. 52:15very distressing because they try to
  1354. 52:17influence my testimony directly but they
  1355. 52:19failed once again
  1356. 52:20and I answered all the questions the
  1357. 52:22best of my ability but it took its toll
  1358. 52:25on me when I'm back to cycle I could no
  1359. 52:27longer endure the hostile day-to-day
  1360. 52:29environment and so by July I went to a
  1361. 52:33company executive explain situation he
  1362. 52:35said you better take some time off and
  1363. 52:37get you head cleared when I did that I
  1364. 52:39went out on medical leave got some
  1365. 52:43professional help
  1366. 52:44got a diagnosis well not diagnosed at
  1367. 52:46that time but I got some professional
  1368. 52:48help to the degree and the point where I
  1369. 52:50knew that the source of my problem was
  1370. 52:52the company and I called him up in
  1371. 52:57September and told him I would never
  1372. 52:58return to work for them they taught me
  1373. 53:01that continue on leave that I had to go
  1374. 53:03and get diagnosed by a psychiatrist
  1375. 53:06which I did I was officially diagnosed
  1376. 53:08by one psychiatrist one psychiatrist and
  1377. 53:11three psychologists is having
  1378. 53:13post-traumatic stress disorder I
  1379. 53:16received long-term disabilities from a
  1380. 53:19medical program which started in January
  1381. 53:21of 87 the day I qualified was the day I
  1382. 53:25got my final noticed that I was
  1383. 53:27terminated I was received my final check
  1384. 53:30and they asked me to send my badges in I
  1385. 53:33did that I received 60% of my former
  1386. 53:35salary for two years and then everything
  1387. 53:39was down to zero now what this really
  1388. 53:43leads to is everyone's Professional
  1389. 53:45Responsibility and I believe it is best
  1390. 53:48explained in this timeless piece by mr.
  1391. 53:52Adolph J Ackerman he wrote in the AAAS
  1392. 53:56he wrote in the I Triple E publication
  1393. 54:00that in 1967 that engineers have a
  1394. 54:05responsibility that goes far beyond the
  1395. 54:07building of machines and systems we
  1396. 54:09cannot leave it to the technical
  1397. 54:11illiterate sorry Ventoux literate and
  1398. 54:12overloaded technical administrators to
  1399. 54:15decide what is safe and for the public
  1400. 54:17good we must tell what we know first or
  1401. 54:20normal administrative channels but when
  1402. 54:22these fails through whatever evidence we
  1403. 54:23can find many claim that it is disloyal
  1404. 54:26to protests sometimes the penalty
  1405. 54:29disapproval loss of status even
  1406. 54:32vilification can be so
  1407. 54:33there today we need more critical
  1408. 54:36pronouncements and public declarations
  1409. 54:38by engineering engineers and high
  1410. 54:40professional responsibilities in some
  1411. 54:42instances such criticism must be severe
  1412. 54:44if we ought to properly serve mankind
  1413. 54:46and preserve our freedom hence it is of
  1414. 54:49the utmost importance that we maintain
  1415. 54:51our freedom of communication in the
  1416. 54:53engineering profession and to the public
  1417. 54:55the decades ahead are bound to be a
  1418. 54:58critical and difficult period and there
  1419. 55:00will be occasions for sharp dissent and
  1420. 55:02strong words if we are to meet our
  1421. 55:05responsibilities
  1422. 55:06close quote I simply recommend
  1423. 55:09practicing the golden rule do unto
  1424. 55:11others as you would have them do unto
  1425. 55:12you
  1426. 55:13unfortunately business in this country
  1427. 55:15especially is has perverted their golden
  1428. 55:17rule and it's called doing to others
  1429. 55:19before they do unto you now don't be
  1430. 55:23expected to protect be protected if you
  1431. 55:25are not willing to protect others from
  1432. 55:26surety professionalism speaking out may
  1433. 55:29or may not extract a price for doing so
  1434. 55:30but I can assure you one thing you will
  1435. 55:33have a clear conscience and a peaceful
  1436. 55:35sleep at night for doing the right thing
  1437. 55:37academia research on whistleblowers
  1438. 55:39provides us some insight actually the
  1439. 55:42industrial government complex strongly
  1440. 55:43discourages whistleblowing
  1441. 55:45if a whistleblower goes outside his
  1442. 55:47organizational culture he is usually
  1443. 55:49severely punished for doing so to send a
  1444. 55:51strong message for others in the
  1445. 55:52organization not to do the same or else
  1446. 55:55they will receive the same end result
  1447. 55:56the industry and government has
  1448. 55:58succeeded very cleverly in deceiving the
  1449. 56:01public about the character and motives
  1450. 56:02of whistle blows the general perception
  1451. 56:04is that whistleblowers are troublemakers
  1452. 56:06and snitches and try to make trouble for
  1453. 56:09their employer while exactly the
  1454. 56:11opposite is the truth extensive research
  1455. 56:13shows that doles has stepped forward
  1456. 56:16with bad news do so to protect the
  1457. 56:18health safety and welfare of the public
  1458. 56:20and their companies but whistleblowers
  1459. 56:24are most often long-term dedicated
  1460. 56:27employees whose only concern is to right
  1461. 56:28or wrong within an organization to
  1462. 56:30prevent somebody from a high-probability
  1463. 56:32injury or death it's really that simple
  1464. 56:35but industry and government has
  1465. 56:36distorted the truth so well that winning
  1466. 56:38vindication for whistleblower is all but
  1467. 56:41impossible I'd like to just quickly
  1468. 56:44summarize just so you have a feel for
  1469. 56:46what
  1470. 56:47happens to people the methods used to a
  1471. 56:49neutralized it whistleblower make the
  1472. 56:51whistleblower instead of the message the
  1473. 56:53issue isolate the whistleblower
  1474. 56:55set the whistleblower up for fall
  1475. 56:57display maximum toughness in selecting
  1476. 57:00charges against the whistleblower you
  1477. 57:02eliminate the whistleblowers job
  1478. 57:04destabilize the whistleblower support
  1479. 57:06base the following some of the methods
  1480. 57:08to neutralize the dissent itself
  1481. 57:10overwhelm the whistleblower by making
  1482. 57:12him or her a struggle for self
  1483. 57:14preservation of career family bank
  1484. 57:17account and even sanity until the point
  1485. 57:19of dissent is put behind waiting way to
  1486. 57:21your survival priorities separate
  1487. 57:24expertise from Authority keep the
  1488. 57:26employees ignorant about what's going on
  1489. 57:28substitute democracy for scientific
  1490. 57:31methods for decision making and last but
  1491. 57:34I believe one of the most important ones
  1492. 57:35is to prevent a written record when a
  1493. 57:38policy is indefensible the goal is to
  1494. 57:40restrict debate to an oral dialogue
  1495. 57:41since it is difficult to accuse somebody
  1496. 57:44of revising an oral dialogue and
  1497. 57:47accountability will be diffused in the
  1498. 57:49event of a tragedy I have to tell you
  1499. 57:51each of the foregoing categories were
  1500. 57:53used against me and my colleagues at
  1501. 57:54various points in times all accept
  1502. 57:57dismissal the conversation I today
  1503. 57:59--tz-- and media made it virtually
  1504. 58:00impossible but I call the dismisses but
  1505. 58:04they did make our lives absolutely
  1506. 58:05miserable on a day-to-day basis now the
  1507. 58:09bottom line in this whole thing and why
  1508. 58:11it's so important is accountability and
  1509. 58:14there's been no accountability to date
  1510. 58:17even today no accountability and more
  1511. 58:19than 500 employees unfortunately will be
  1512. 58:21the ones that have accountability
  1513. 58:23extracted from them at this point in
  1514. 58:25time there have been over 1,000
  1515. 58:27employees laid off at the facility at
  1516. 58:29Morton Thiokol out of about 8,000 people
  1517. 58:31and that's very very severe in northern
  1518. 58:34Utah there are no other jobs to go to
  1519. 58:36and so some of these people are
  1520. 58:38unfortunately actually have to walk away
  1521. 58:39from their homes the lack of
  1522. 58:41accountability has actually produced an
  1523. 58:43incredibly browsing nozzle joint
  1524. 58:46redesign that they're flying today the
  1525. 58:48joint actually begs failure by Murphy's
  1526. 58:50Laura once again just as the original
  1527. 58:52joint that I showed you I have some
  1528. 58:54suggested solutions eirick I suggest
  1529. 58:57that we require the passage of the EIT
  1530. 58:59exam as a
  1531. 59:00requisite for obtaining an engineering
  1532. 59:02degree now don't all moan and groan I'm
  1533. 59:05not asking you to do anything I haven't
  1534. 59:06already done on the I did it the hard
  1535. 59:07way
  1536. 59:08I took the EIT being out of school over
  1537. 59:1230 years so it can be done and then take
  1538. 59:16the the P exam and pass it and get
  1539. 59:19licensed now the reason I am I
  1540. 59:21suggesting is the code of ethics as a
  1541. 59:24very effective club when a manager comes
  1542. 59:26up to you and asked you to do something
  1543. 59:28unethical you can simply refer him to
  1544. 59:30the code of ethics and ask him is he
  1545. 59:33asking you to violate this code of
  1546. 59:34ethics you see the effectiveness that
  1547. 59:36this potentially could have I believe it
  1548. 59:38would really work and put the
  1549. 59:40decision-making process back in the
  1550. 59:41hands of the engineering and the
  1551. 59:43technical people and it would also avoid
  1552. 59:45the current shameful paradox that it
  1553. 59:47exists in this country at the present
  1554. 59:48time really the only people that need to
  1555. 59:50be licensed as civil engineers who build
  1556. 59:52our roads bridges and buildings most of
  1557. 59:54the others of us have a huge industrial
  1558. 59:56exemption and not need to be licensed
  1559. 59:58but consider the paradox
  1560. 1:00:00what does more harm to you as an
  1561. 1:00:02individual the roadbed that you drive a
  1562. 1:00:05car over or the car that you're riding
  1563. 1:00:06in did you ever think about the
  1564. 1:00:08airplanes you fly in I did the stress
  1565. 1:00:10analysis and some of that stuff I'm not
  1566. 1:00:12licensed wasn't licensed at the time
  1567. 1:00:14does that give you a warm feeling it
  1568. 1:00:17doesn't give me a very warm feeling and
  1569. 1:00:19it's a terrible paradox when you really
  1570. 1:00:20look at it as to what it represents the
  1571. 1:00:23huge industrial exemption actually
  1572. 1:00:25provides a huge resource pool of a
  1573. 1:00:28renewable resource of Engineers and
  1574. 1:00:30that's why it's done and it's a way to
  1575. 1:00:32promote cheap labor
  1576. 1:00:33in an overturning business community
  1577. 1:00:37well I hope is that attorneys can make
  1578. 1:00:41inroads into the into the law and cause
  1579. 1:00:43the transfer of the engineering code of
  1580. 1:00:45ethics to management and restore the
  1581. 1:00:47technical decision-making to the
  1582. 1:00:48technical people but if this fails I
  1583. 1:00:50feel that the long term solution really
  1584. 1:00:52rests with university university
  1585. 1:00:54education and it rests with them to
  1586. 1:00:57teach students the benefits of combining
  1587. 1:00:59science technology and society issues
  1588. 1:01:01towards the upgrading of ethical
  1589. 1:01:02decision making within industry and
  1590. 1:01:04government in conclusion I will never
  1591. 1:01:07forget and I hope this nation will never
  1592. 1:01:10forget especially the engineering
  1593. 1:01:11community
  1594. 1:01:12the supreme sacrifice that the seven
  1595. 1:01:14challenge astronauts made for forfeiting
  1596. 1:01:16their lives for such an irresponsible
  1597. 1:01:17launch decision
  1598. 1:01:19maybe we always remember astronauts Kobe
  1599. 1:01:22Smith McNair Onizuka Resnick Jarvis and
  1600. 1:01:30McAuliffe for the dedication and courage
  1601. 1:01:33to this nation's space program
  1602. 1:01:35I implore all of you not to dwell on any
  1603. 1:01:39of the negative aspects that you've just
  1604. 1:01:40heard but use those conditions that
  1605. 1:01:45you've heard as a positive lesson on how
  1606. 1:01:48to recognize and act upon
  1607. 1:01:51confrontational situations that you may
  1608. 1:01:54encounter in your careers and I assure
  1609. 1:01:56you you will encounter them albeit in a
  1610. 1:01:59much lesser visible environment I hope
  1611. 1:02:02we can all learn together from past
  1612. 1:02:04organizational misconduct and bring
  1613. 1:02:07about change toward practicing the
  1614. 1:02:08golden rule in business and government
  1615. 1:02:10to significantly reduce unethical
  1616. 1:02:13decision making practices thank you very
  1617. 1:02:15much
  1618. 1:02:22oh yes yes sir that was a marvelous
  1619. 1:02:31presentation but I want to ask you why
  1620. 1:02:33you think that universities are the
  1621. 1:02:35proper place to teach ethics we think
  1622. 1:02:37that the ethical standards of
  1623. 1:02:39universities are it sufficiently high or
  1624. 1:02:42different from the general community if
  1625. 1:02:44I want to be whistle blown off stand up
  1626. 1:02:46at that desk
  1627. 1:02:47what I can say about universities would
  1628. 1:02:49be just about the same is what you have
  1629. 1:02:51said so I don't believe that the ambient
  1630. 1:02:54at the university is very ethical it's
  1631. 1:02:56just hidden no but you have to
  1632. 1:02:58understand that that the real effect of
  1633. 1:03:02an engineering education is to become
  1634. 1:03:04socially inept we are technically sharp
  1635. 1:03:07but socially inept as hell and if you
  1636. 1:03:09don't give people the rudimentary basics
  1637. 1:03:11on what to expect
  1638. 1:03:12then you're expecting them to respond to
  1639. 1:03:14situations that they've never been
  1640. 1:03:15schooled or even have an inkling of a
  1641. 1:03:18being thrown into the Lions Den and I
  1642. 1:03:21believe that through a case study such
  1643. 1:03:24as that I presented here that there are
  1644. 1:03:25many fruitful areas of discussion not
  1645. 1:03:28that you will make everybody an ethical
  1646. 1:03:29person but you will give them the basic
  1647. 1:03:31tools to make an informed decision but
  1648. 1:03:34now you expect people who are no more
  1649. 1:03:38ethical than others to lead ethical
  1650. 1:03:41discussions I you teach things all the
  1651. 1:03:44time in addition all about engineering
  1652. 1:03:47as well well you use this Epic's how do
  1653. 1:03:51we know Epic's we are the teachers and
  1654. 1:03:54we don't know it are you telling me that
  1655. 1:03:56you can't take what I just gave you
  1656. 1:03:58today and use it as a video tape
  1657. 1:04:00presentation as a segment of your class
  1658. 1:04:02and actually motivate people towards a
  1659. 1:04:05understanding of what they need to
  1660. 1:04:07expect when they get into industry
  1661. 1:04:08whether you're unethical or not if you
  1662. 1:04:10can't do that then you don't have a very
  1663. 1:04:13good rapport with your students I don't
  1664. 1:04:15think that's what have a very good
  1665. 1:04:16rapport with their students we have some
  1666. 1:04:18students here and they can tell us how
  1667. 1:04:20good or up the horrors they have with
  1668. 1:04:21their professors well well I'll tell you
  1669. 1:04:24I've been at many of the major
  1670. 1:04:25universities around this country and the
  1671. 1:04:27student bodies are the ones that are
  1672. 1:04:29actually asking for these courses to be
  1673. 1:04:31taught so that they do not go out with
  1674. 1:04:33blinders on and if the universities
  1675. 1:04:36respond to that then we are in a sad
  1676. 1:04:38state of affairs in this country a point
  1677. 1:04:46I wanted to clear out when you said that
  1678. 1:04:48the engineering group on this meeting
  1679. 1:04:53the night before before the management
  1680. 1:04:55reversed itself the engineering
  1681. 1:04:59participants were unanimous and
  1682. 1:05:01recommending that the launch not take
  1683. 1:05:03place and that this information not this
  1684. 1:05:07recommendation not to launch had been
  1685. 1:05:09transmitted to decision makers within
  1686. 1:05:12NASA is that right that's correct so
  1687. 1:05:14they were clearly appraised of the fact
  1688. 1:05:17that the technical people had
  1689. 1:05:19recommended not to launch that's right
  1690. 1:05:23the other recommendation knew that it
  1691. 1:05:30was not based on the same technical it
  1692. 1:05:35was not repetition but was simply a
  1693. 1:05:39management appraisal of the gamble no no
  1694. 1:05:43you missed the sequence of events what
  1695. 1:05:45we did that day was we as engineers
  1696. 1:05:48convinced our own in-house people not to
  1697. 1:05:50launch and we had the technical
  1698. 1:05:51rationale to support that when we were
  1699. 1:05:54finished convincing our own in-house
  1700. 1:05:55people about that we had informal
  1701. 1:05:57discussions with NASA Marshall Space
  1702. 1:05:59Flight Center we had no view graphs but
  1703. 1:06:01we had informal discussions and
  1704. 1:06:02expressed in verbalized our concerns and
  1705. 1:06:05when they heard our concerns verbalized
  1706. 1:06:07they became very antsy about what we
  1707. 1:06:10were talking about and they asked us to
  1708. 1:06:12formalize our concerns in a formal
  1709. 1:06:14presentation on a telecon that evening
  1710. 1:06:16which we did with a formal hookup
  1711. 1:06:17between three two centers and us at the
  1712. 1:06:20plant we actually gave our engineering
  1713. 1:06:22presentation and the expectation had
  1714. 1:06:25never wavered from the fact that we were
  1715. 1:06:27there for the sole purpose of stopping
  1716. 1:06:28the launch as was the initial result
  1717. 1:06:31what happened at night is we ran into a
  1718. 1:06:33buzzsaw with a customer namely NASA who
  1719. 1:06:36actually reversed their posture in in
  1720. 1:06:38instead of forcing us to prove that it
  1721. 1:06:40was safe to launch which was the normal
  1722. 1:06:42occurrence they were actually put us in
  1723. 1:06:45a posture to prove that it was not safe
  1724. 1:06:46to launch and of course we couldn't do
  1725. 1:06:48that
  1726. 1:06:48all I could speak in is terms of
  1727. 1:06:51probabilities of failure and no numbers
  1728. 1:06:53mind you because I had no numbers but I
  1729. 1:06:56have two eyes and I 20 years at 27 years
  1730. 1:06:59experience and a good feel for what
  1731. 1:07:02these little babies do and everybody
  1732. 1:07:05else knew about it for an engineering
  1733. 1:07:08standpoint too and they listened you see
  1734. 1:07:10we were successful what we what we
  1735. 1:07:12actually ran into that night was a
  1736. 1:07:14totally unexpected customer reaction
  1737. 1:07:18that seems to me to exonerate thiokol
  1738. 1:07:21that if that they have made possible the
  1739. 1:07:25vehicle for communicating the concern of
  1740. 1:07:28the technical people your voice had had
  1741. 1:07:31a hearing and your colleagues had had a
  1742. 1:07:33hearing and your customers chose to
  1743. 1:07:37ignore the technical information and
  1744. 1:07:39recommendations they were receiving from
  1745. 1:07:41the technical people and it seems to me
  1746. 1:07:44that that your company people should
  1747. 1:07:48have been thoroughly protected by no not
  1748. 1:07:51at all because they actually ultimately
  1749. 1:07:53capitulated as manages and gave
  1750. 1:07:56permission to launch
  1751. 1:07:57oh yes it does because what it did was
  1752. 1:08:04it what it did was it showed that the
  1753. 1:08:06people who ran the company were now
  1754. 1:08:08coming up and saying you remember that
  1755. 1:08:11chart I showed you it implied it implied
  1756. 1:08:14that there was a engineering review that
  1757. 1:08:16took place see the implication was that
  1758. 1:08:19the engineering assessment is that it
  1759. 1:08:21implied that the engineers participated
  1760. 1:08:24in that caucus when in fact that was not
  1761. 1:08:26true and so they actually had deceived
  1762. 1:08:31NASA on the receiving end of this
  1763. 1:08:33information as to what happened see we
  1764. 1:08:35were on mute
  1765. 1:08:36they couldn't hear us and we couldn't
  1766. 1:08:38hear them this was a closed hearing a
  1767. 1:08:39closed meeting and so they did and they
  1768. 1:08:43do deserve as as matter of fact the
  1769. 1:08:46signers and manufacturers and producers
  1770. 1:08:47of this booster I assigned 75% of the
  1771. 1:08:50blame for the launch on fire call people
  1772. 1:08:52on a human that you may think that
  1773. 1:08:54that's harsh but dammit it's their
  1774. 1:08:56hardware and they have a fiduciary
  1775. 1:08:58responsibility to justify that the
  1776. 1:09:01that to give the information that their
  1777. 1:09:04hardware is ready for launch and when
  1778. 1:09:06they say that their hardware is ready
  1779. 1:09:07for launch by gosh it should be ready
  1780. 1:09:09for launch without any crap shoot or
  1781. 1:09:12gamble in pressing that button and so
  1782. 1:09:14they should be held and put their feet
  1783. 1:09:16to the fire about 75% of the blame now
  1784. 1:09:19if you internalize that same type of
  1785. 1:09:21percentage within Morton Thiokol I say
  1786. 1:09:23that the general manager of our plant
  1787. 1:09:25should be accorded 75% of the blame
  1788. 1:09:27because he's the one that created the
  1789. 1:09:29ultimate internal pressure in that
  1790. 1:09:30caucus when he and it finalized that
  1791. 1:09:33with his direction to the vice
  1792. 1:09:35presidential era to play ball and so I
  1793. 1:09:38apportion 75% of the blame for that
  1794. 1:09:40launch decision on the general manager
  1795. 1:09:42and in that plant now you can agree or
  1796. 1:09:45disagree with that but the fact is they
  1797. 1:09:46cannot dodge the responsibility for
  1798. 1:09:49making this decision I thought at that
  1799. 1:09:51night and I still think it today at this
  1800. 1:09:53point in time that the reason they did
  1801. 1:09:55what they did is that we were in
  1802. 1:09:57negotiations for fall on sole source
  1803. 1:10:00contract without any competition that
  1804. 1:10:03would keep them making boosters into the
  1805. 1:10:04late 1990s without any competition
  1806. 1:10:06whatsoever yeah but don't you think the
  1807. 1:10:08NASA representatives knew that pressure
  1808. 1:10:10that was on them and that they they had
  1809. 1:10:12a very clear idea of what the technical
  1810. 1:10:14problems were and they used this
  1811. 1:10:18reversal position of your Thiokol
  1812. 1:10:21managers simply to do what they wanted
  1813. 1:10:24to do in the first place well I think
  1814. 1:10:25that's correct and now I think that
  1815. 1:10:26actually is underlined by the fact that
  1816. 1:10:28they didn't ask any deeper probing
  1817. 1:10:29questions during during the receipt of
  1818. 1:10:31that answer and I actually had a
  1819. 1:10:33presidential commission member who will
  1820. 1:10:35remain nameless tell me there Roger it
  1821. 1:10:37didn't make any difference what you guys
  1822. 1:10:38did that night NASA was going to launch
  1823. 1:10:40anyways period and so our guys would
  1824. 1:10:43have come out way ahead if they just
  1825. 1:10:45hung up the telephone conversation I
  1826. 1:10:51know that but I can make just and I
  1827. 1:10:54agree this great circumstantial evidence
  1828. 1:10:56for that for that position but there's
  1829. 1:10:58just as strong and evidence on the other
  1830. 1:11:00side of that coin for NASA creating
  1831. 1:11:01their own pressure this was NASA's
  1832. 1:11:03premier PR opportunity since landing a
  1833. 1:11:06man on the moon think about that
  1834. 1:11:08now after that disaster now seven
  1835. 1:11:11through a major reorganization
  1836. 1:11:14and change our management do you think
  1837. 1:11:17any of this would be prevented by the
  1838. 1:11:20change of Management Center Styles they
  1839. 1:11:22don't know well the floor the floor in
  1840. 1:11:24that statement is major they did not go
  1841. 1:11:26through a major reorganization they went
  1842. 1:11:28through a cosmetic reorganization which
  1843. 1:11:31means absolutely nothing
  1844. 1:11:32the the motivation for Carson's schedule
  1845. 1:11:35is alive and well people it's alive and
  1846. 1:11:38well in and you don't have to take my
  1847. 1:11:40word for it
  1848. 1:11:41just go back and read the newspapers
  1849. 1:11:43since they returned the flight NASA
  1850. 1:11:46rolled out the return to flight vehicle
  1851. 1:11:48on the 4th of July
  1852. 1:11:50rah-rah-rah they no sooner got it out to
  1853. 1:11:53the pad when they developed major fuel
  1854. 1:11:56leaks which they acknowledged an
  1855. 1:11:58oppression in a press release that they
  1856. 1:12:00never ever have fixed on a pad they
  1857. 1:12:02always roll back into the Vehicle
  1858. 1:12:04Assembly Building and then proceeded to
  1859. 1:12:06fix it on the pad there there are
  1860. 1:12:09literally hundreds of examples since the
  1861. 1:12:12return to flight like this that will
  1862. 1:12:13absolutely conclusively prove to you
  1863. 1:12:16that the organization is still badly
  1864. 1:12:18broken over 10 scientific astronauts
  1865. 1:12:22have resigned from the program why I ask
  1866. 1:12:25you would scientific astronauts all PhDs
  1867. 1:12:29all very talented individuals all who
  1868. 1:12:32worked their fingers to the bone to get
  1869. 1:12:34into the astronaut corps program why
  1870. 1:12:36would they give up the premier technical
  1871. 1:12:38opportunity this century if there still
  1872. 1:12:40wasn't something really bad in the
  1873. 1:12:42program and they would see seeing
  1874. 1:12:44themselves you as the sacrificial lambs
  1875. 1:12:46once again why would Sally Ride quit
  1876. 1:12:48shortly after she issued a report
  1877. 1:12:50doesn't make sense doesn't make sense at
  1878. 1:12:54all unless the system is still screwed
  1879. 1:12:56up
  1880. 1:12:56I had numerous phone calls both with
  1881. 1:12:59inside of NASA and with inside Morton
  1882. 1:13:01Thiokol and the message was loud and
  1883. 1:13:03clear
  1884. 1:13:03Roger it is business as usual NASA set
  1885. 1:13:07up a a snitch program an internal snitch
  1886. 1:13:10program that would read that people
  1887. 1:13:13would remain anonymous and it goes
  1888. 1:13:14through the Columbus NASA facility the
  1889. 1:13:17first person that reported a very severe
  1890. 1:13:20problem and it had to do with the
  1891. 1:13:22o-rings somebody had actually slipped
  1892. 1:13:24the o-rings I guess with a razor blade
  1893. 1:13:26and they were hoping to draw attention
  1894. 1:13:28to two problems in a manufacturer the
  1895. 1:13:30o-ring seal that was a hell of a way to
  1896. 1:13:32do it but but that's what they did do
  1897. 1:13:34you know that the first test case
  1898. 1:13:36through this supposedly anonymous system
  1899. 1:13:38they identified the individual what do
  1900. 1:13:40you think that did to the system
  1901. 1:13:42it totally diffused the system as being
  1902. 1:13:44operative do you think that things have
  1903. 1:13:47changed at NASA I just came from the
  1904. 1:13:49nest it's guarded Space Center last week
  1905. 1:13:51I got the ultimate invite to talk to my
  1906. 1:13:53colleagues at NASA at a different center
  1907. 1:13:55of course but the fact that Matt is
  1908. 1:13:57there scared to death about this
  1909. 1:13:59upcoming launch after I talk to them
  1910. 1:14:00about this this incredibly lousy joint
  1911. 1:14:03redesigned you know let me show you you
  1912. 1:14:08want you want to see you want ammunition
  1913. 1:14:10I'll give you an addition this is the
  1914. 1:14:12redesigned joint that I have no problem
  1915. 1:14:15with technically I don't like it as the
  1916. 1:14:17best design but I have no problem safety
  1917. 1:14:19wise you can recognize the original
  1918. 1:14:21configuration of the joint in here see
  1919. 1:14:23the crosshatch section that's the new
  1920. 1:14:24additional piece that's now machined as
  1921. 1:14:27part of the tang and this purpose is a
  1922. 1:14:29capture feature to keep this leg from
  1923. 1:14:30lifting off this is now an interference
  1924. 1:14:33fit right here okay these parts is
  1925. 1:14:36supposed to reuse nineteen times you you
  1926. 1:14:39really think they're going to get
  1927. 1:14:40nineteen uses out of these things
  1928. 1:14:41after this interference fit is gold and
  1929. 1:14:44chewed up every time they assemble this
  1930. 1:14:45thing I don't think so
  1931. 1:14:47but as far as it's or rings occur in
  1932. 1:14:49their level rings they add another
  1933. 1:14:50o-ring it's a vital ring and but this
  1934. 1:14:54seal will always remain compressed and
  1935. 1:14:57always get more compression as the
  1936. 1:14:59vehicle is pressurized so from that
  1937. 1:15:00standpoint it's not bad when all these
  1938. 1:15:06go out this tries to go in but it can't
  1939. 1:15:09anymore because this won't let it
  1940. 1:15:11and as this mutual interface moves it
  1941. 1:15:14just causes this comparing to stay
  1942. 1:15:16compressed now see I had recommended a
  1943. 1:15:18wire mesh elastomeric impregnated seal
  1944. 1:15:23for this position that is used in the
  1945. 1:15:26oil industry it can withstand thirty
  1946. 1:15:28five thousand psi in two thousand
  1947. 1:15:30degrees Fahrenheit for a long period of
  1948. 1:15:33time way in excess of two minutes and
  1949. 1:15:35they put a Viton o-ring seal in there
  1950. 1:15:37you know I'm really ashamed to admit
  1951. 1:15:40that I told them how to make this joint
  1952. 1:15:42they they had this coming down
  1953. 1:15:45originally right here and they could not
  1954. 1:15:47figure out how to get a machining quill
  1955. 1:15:49and they had a machine the slot and like
  1956. 1:15:51a stupid jerk I told them to just had to
  1957. 1:15:53relieve this and it could have machined
  1958. 1:15:54it or else they would had to come up
  1959. 1:15:55with a different design but I have no
  1960. 1:15:57problem with this from a safety
  1961. 1:15:58standpoint no problem at all it's a belt
  1962. 1:16:01and suspenders
  1963. 1:16:02they also have heaters on the joint to
  1964. 1:16:04keep them nice and toasty warm okay this
  1965. 1:16:07is the joint I really have a problem
  1966. 1:16:08with this is a joint that I believe that
  1967. 1:16:12none of you is engineering students or
  1968. 1:16:14engineering professors would even design
  1969. 1:16:16in your home workshop this is an
  1970. 1:16:17abortion what we have here and you
  1971. 1:16:21recognize the joint the nozzle fixed
  1972. 1:16:23housing this is the F dome they've got a
  1973. 1:16:25little bit different character of
  1974. 1:16:27insulation they have what they call
  1975. 1:16:29split flap which it allows the stress to
  1976. 1:16:31be taken off this this opening they have
  1977. 1:16:33and he's have been here and they have
  1978. 1:16:35another ol ring is the level rings again
  1979. 1:16:37right there but this is not used as a
  1980. 1:16:39seal I'll explain that in a minute
  1981. 1:16:41there's the original primary seal the
  1982. 1:16:43original secondary seal and now they've
  1983. 1:16:46drilled 100 radio holes between the
  1984. 1:16:50original primary and secondary seal
  1985. 1:16:52installed 100 bolts and underneath the
  1986. 1:16:55head of these bolts they put the magic
  1987. 1:16:56seals called stato seals they are washes
  1988. 1:17:00and you guessed it o rings on the ID
  1989. 1:17:04it's a blind assembly people by its very
  1990. 1:17:07name stat means statics that o seal this
  1991. 1:17:11piece relative to this piece moves in
  1992. 1:17:14the axial direction roughly 8 to 10
  1993. 1:17:16thousandths of an inch
  1994. 1:17:17this piece moves relative to this piece
  1995. 1:17:20some amount unknown in a circumferential
  1996. 1:17:23plane because when these assembled
  1997. 1:17:25they're not round I assure you they are
  1998. 1:17:27round when they're pressurized to a
  1999. 1:17:29thousand psi and so you have relative
  2000. 1:17:32motion this joint is designed to have a
  2001. 1:17:34gap it's designed to have a gap who in
  2002. 1:17:38their right mind would actually clamp
  2003. 1:17:41against an airspace against the gap that
  2004. 1:17:45was designed a piece of equipment it was
  2005. 1:17:48designed have a gap in it what
  2006. 1:17:49means is that at a hundreds of street
  2007. 1:17:51points you have metal metal contact and
  2008. 1:17:52in between 100 discrete points you have
  2009. 1:17:54a daisy effect with a gap in between the
  2010. 1:17:57bolts it will act very similar not in
  2011. 1:18:00magnitude but very similar in technique
  2012. 1:18:02of deflection as the previous joint now
  2013. 1:18:05remember we had already gotten past a
  2014. 1:18:07primary ring sale in April 1985 flight
  2015. 1:18:10this is not a test it was a real flight
  2016. 1:18:12we ever get past the primary seal again
  2017. 1:18:14we now present 101 potentially pets
  2018. 1:18:18instead of one that we had originally I
  2019. 1:18:20had also proposed a metal seal here
  2020. 1:18:23which would have not only taken the
  2021. 1:18:24temperature but would have been
  2022. 1:18:26impervious to erosion should we ever get
  2023. 1:18:28past my recommendation for this joint
  2024. 1:18:31was to simply take these F domes put
  2025. 1:18:33them up in a vertical turret lathe cut a
  2026. 1:18:35cylindrical true service extend this
  2027. 1:18:38they had to make all these new pieces
  2028. 1:18:39anyways here extend this out import a
  2029. 1:18:42register that would actually keep this
  2030. 1:18:45piece from moving in and out like it had
  2031. 1:18:47done before it would minimize it okay
  2032. 1:18:49now get back to the adhesive I could I
  2033. 1:18:51submit to you that if you had gone
  2034. 1:18:52around and taking a poll with that call
  2035. 1:18:54and asked is anybody ever concerned with
  2036. 1:18:58hockey ass getting past this adhesive
  2037. 1:18:59the answer including me would have been
  2038. 1:19:01not on your life it'll never get past it
  2039. 1:19:04he Civ Clark guys can never even get to
  2040. 1:19:06this first sale this is considered a
  2041. 1:19:08wiper seal and the purpose of this is to
  2042. 1:19:10keep this adhesive from following the
  2043. 1:19:13real seal during assembly
  2044. 1:19:14now let me ask you a question if the
  2045. 1:19:16purpose of this seal is to keep that
  2046. 1:19:17adhesive from following that seal during
  2047. 1:19:19assembly does not it follow that that
  2048. 1:19:22adhesive will follow this seal during
  2049. 1:19:24assembly guess what happened the first
  2050. 1:19:27two development tests of this joint a
  2051. 1:19:29hot gas test and a coal gas test they
  2052. 1:19:32got gas right through here
  2053. 1:19:35passed adhesive one gentleman told me
  2054. 1:19:37that it stopped here and the other
  2055. 1:19:38gentleman told me I went all the way up
  2056. 1:19:40to the primary sale two out of two test
  2057. 1:19:43failures in the redesign of this joint
  2058. 1:19:45and this joint still went forward and is
  2059. 1:19:47flying today now do you think something
  2060. 1:19:50has changed at the agency I sure as hell
  2061. 1:19:52don't think something's changed at the
  2062. 1:19:53agency this is the type of crap that
  2063. 1:19:56they still put out this is a Murphy of
  2064. 1:19:59our type joint this is the joint
  2065. 1:20:01why this disjoint is why I don't watch
  2066. 1:20:04launches anymore
  2067. 1:20:05I am absolutely afraid to watch the
  2068. 1:20:09launch because of the fear of failure in
  2069. 1:20:11real time again I could probably see a
  2070. 1:20:13videotape but not in real time that was
  2071. 1:20:15too much to go through that one time and
  2072. 1:20:17I won't do it again but this is what
  2073. 1:20:18we're faced in a program today thank you
  2074. 1:20:22thank you very much the opportunity to
  2075. 1:20:25talk to mr. Beaujolais again and the
  2076. 1:20:27refreshments and old W building and I
  2077. 1:20:29thank you again I think we all
  2078. 1:20:31appreciated your presentation
  2079. 1:20:33[Applause]

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