Problem Solving | Lessons from Apollo 13

Problem Solving | Lessons from Apollo 13

Overcoming Adversity: The Problem Solving Strategies of Apollo 13 Mission

On April 11, 1970, Apollo 13 lifted off from its launch pad at Kennedy space center. On board were:

  • Commander Jim Lovell

  • Command Module Pilot Jack Swigert

  • Lunar Module Pilot Fred Haise

The mission was to fly to the moon and do some exploring and various scientific experiments. Three days into the flight, on April 14th, at a distance of about 200,000 miles from the earth, Apollo 13’s mission changed dramatically. Instead of a mission to the moon, it became a race for survival for the 3 astronauts on board. Let’s examine how the crew and mission control used problem solving strategies to get the 3 men back to earth alive.

Identify Your Goals for Problem Solving

Part of problem solving is decision making, so let’s take a brief look at what goes into making a decision. The process of decision making is “Deciding Among Various Alternatives”. This begins with the preparation stage where you identify your goals. The original goal for the mission was to fly to the moon.... due to some unforeseen circumstances, the goal changed.

Basic Steps in Decision Making

  • Identify the Decision - The most obvious step and likely the easiest... when you are faced with a decision, you usually know it however it is best to clearly define the decision.

  • Gather Information - Collect as much information as you have available to help see a path forward. A little creative thinking is helpful at this phase. Look at both internal and external sources of information at this point.

  • Identify Alternatives - While you collect information, and start to identify various directions, you will start to see alternate paths. List all of those new options.

  • Measure all of the Evidence - Start to visualize all of the various paths and how it would look if you carried each of them through completion. This is a difficult internal process but try and imagine reaching your goal and you will start to favor specific alternatives and realize some of them appear to have a higher success rate. List those in priority order based on your own sense of value (your value system).

  • Choose among Alternatives - After you have measured all of the evidence, you will be ready to select a direction that is best for you. You may also see multiple choices that appear to satisfactory and appear to have a high potential for success.

  • Implementation of the Decision - Now is the time to start implementing your decision and mentally (or physically) test what was listed in step 5.

  • Review Your Decision - At this point, you have moved from identification to gathering info, to looking at alternatives, and measuring evidence. Now with one or more alternatives being mentally or physically tested yo should now review to confirm if you are satisfying the original intent (confirming the intent of your decision). If the decision is not meeting your needs, you should go back to previous steps and possibly gather more information.

Organize Thoughts and Data

Part of problem solving is decision making, so let’s take a brief look at what goes into making a decision. The process of decision making is “Deciding Among Various Alternatives”. This begins with the preparation stage where you identify your goals. The original goal for the mission was to fly to the moon.... due to some unforeseen circumstances, the goal changed.

Part of decision making is actually carrying out the decision. Apollo 13 took off; everything went well on the way to the moon. Since this was the third visit to our planet’s companion, it had almost became a routine flight, until a loud noise, accompanied by malfunctions in the electrical system and a short blasts of the control thrust'ers led the astronauts to believe they might have been struck by a meteorite.

Define the Problem Using Facts

From one moment to the next, the routine was interrupted and everyone switched to problem solving mode. In order to determine what the problem was and to find a course of action to solve it, the crew and mission control had to use critical thinking. They asked themselves 4 important questions.

  • What is the initial set of facts?

  • What is it that we need to solve?

  • What parts of the problem appear to be the most critical to finding a solution?

  • Is there some information that can be ignored?

The first thing to do when solving a problem is to find out what the problem is. The crew, with the help of telemetry from mission control, was assessing the facts of the problem. It turned out that oxygen from the number 1 tank leaked out into space. With the oxygen gone, there would be no more air to breath and no more fuel for generating electricity. The command module was now running on battery power only and the batteries life expectancy was very limited. Now that the problem was identified, the next step was to determine what was needed to solve the problem. It became clear that in order to survive they would need to shut down the command module and use the lunar module as a “lifeboat”. This was an alternative that was readily available because it had previously been suggested during an earlier training simulation.

Prioritize Critical Information

The next question was “which part of the problem appears to be the most critical to finding a solution”? It turned out that the electrical power was the most crucial asset needed in order to survive, but this was also the most limited asset.

The command module was already shut down, but they still had to conserve as much energy as possible. So they stopped all live TV broadcasts, turned down the heaters, and even limited the radio communications to the least amount.

Determine Critical Factors

Lastly, they looked at what information could be ignored. One would think that knowing about the amount of oxygen available was the most important information they would need in order to survive, but the lunar module had enough oxygen to get re-pressurized after each surface excursion. The fact that there would not be any extra-vehicular excursions on the moon meant that the lunar module would not lose its oxygen pressure at all. Therefore the information about the amount of oxygen available became the least important, for the time being. However, the goal of the mission had changed from going to the moon, to bringing the astronauts back to earth alive.

As a matter of absolute necessity, they needed to determine how much time they had left to keep the astronauts on board alive. They calculated backwards from the time all the resources to survive were depleted (to identify the exact time when oxygen and heat would cease to exist) and base a course of action on that.

Which strategies did they use to solve this problem and accomplish the goal?

First, they worked as a team. The crew in space worked with mission control and the engineers on earth to find the best possible solutions. You need to know… Assembling a team with the knowledge required to understand the product or process is essential however knowledge about the product and process is not enough. Ensuring your team has the problem solving skills required to build an effective framework of problem solving while under pressure and a short timeline is essential in today’s competitive market. Time was the most crucial element in determining which decisions they had to make. Since this was such a huge problem they used another strategy. They broke the problem down into smaller, more manageable pieces (and assigned specific assignments and tasks to various staff based on their experience and expertise). For example, they had to find the best alternative to reverse the course of Apollo 13 back to earth. The sub-problem was the spacecraft was already in the moon’s gravitational sphere of influence. To use the service module’s engine to reverse course did not make a lot of sense. In addition to that, it was not clear if the engine had suffered damage from the explosion, so they opted for the circumlunar free return option. This used the moon’s gravitational pull like a slingshot to propel Apollo 13 back towards earth. They used charts, drawings and calculations to determine the course of the craft and the precise timing of firing the engine to provide the boost needed to propel them all the way back to earth. Breaking the big problem down into smaller one’s is a great problem solving strategy.

Another problem arose that could have made any attempt to bring the crew back safely, obsolete. Lithium hydroxide, which removes carbon dioxide from the air, became scarce.

Problem Solving Perspectives

Although they had enough lithium hydroxide canisters on board the command module, the square cartridges would not fit in the lunar module, which took round cartridges. So they used another critical thinking strategy called “taking another perspective”. They literally were “thinking outside the box”. The engineers on earth came up with the solution of adapting the square command modules canisters to the round lunar module fittings. They called it “the mailbox” since that is what the final modified CO2 scrubber unit looked like.

Perhaps the trickiest problem to solve was how to power up the command module before reentry into earth’s atmosphere. If there was too big a power draw during the power up phase, the batteries would collapse, which would leave the space capsule uncontrollable. They kept refining the solutions until they could be sure that they had a reliable power up procedure.

Creative Solutions for a Difficult Problem

By eliminating components that were not absolutely necessary and by refining the sequence of the power up, they were able to reduce the overall power requirements to a level that allowed them to successfully power up the command module. After the systems in the command module were up and running, Lovell, Swigert and Haise moved from the lunar module and prepared for reentry. They first jettisoned the service module. As the module floated away, the crew saw the extent of the damage for the first time. Then they separated from the lunar module, which had been their lifeboat for the last 4 days. It was time for the dangerous last phase of the mission; reentry into earth’s atmosphere. On April 17th, 1970, after a perilous 6 day flight through space, Odyssey finally splashed down into the south Pacific. The crew was picked up by the aircraft carrier Iwo Jima. Apollo 13 was a great example of how critical thinking and the various strategies of problem solving were used to bring the 3 astronauts back to earth alive.

Jeffrey K. Liker is a professor of industrial and operations engineering at the University of Michigan and a well-known author in the field of lean manufacturing and the Toyota Production System.

  • Toyota Culture:The Heart and Soul of the Toyota Way (co-authored with Michael Hoseus)

  • Toyota Talent:Developing Your People the Toyota Way (co-authored with David Meier)

Lean Manufacturing Resources:

  • Lean Thinking:Banish Waste and Create Wealth in Your Corporation by James P. Womack and Daniel T. Jones

  • Learning to See: Value Stream Mapping to Create Value and Eliminate MUDA by Mike Rother and John Shook

  • Lean Six Sigma:Combining Six Sigma Quality with Lean Production Speed by Michael L. George

  • The Goal: A Process of Ongoing Improvement by Eliyahu M. Goldratt

  • Gemba Kaizen:A Commonsense Approach to a Continuous Improvement Strategy by Masaaki Imai

  • Kaizen: The Key to Japan's Competitive Success by Masaaki Imai

  • Lean Enterprise:How High-Performance Organizations Innovate at Scale by Jez Humble, Joanne Molesky, and Barry O'Reilly