Before astronauts climb into the space shuttle to fly to the International Space Station or before a NASA probe begins to unravel the mysteries of the universe, Boeing payload processing specialists have spent months and sometimes years preparing for the mission.

Boeing recently won the Checkout, Assembly and Payload Processing Services (CAPPS) contract from NASA. The contract continues the work Boeing did under the Payload Ground Operations Contract (PGOC) since 1987. CAPPS is a four-year contract with two three-year options. The contract’s value is about $332 million, and rises to about $810 million if NASA exercises both options.

“Payload processing is a critical, but little publicized spaceflight task,” said John Elbon, Boeing CAPPS manager. “In space, there’s really not a second chance to get it right, so our team makes sure everything works the first time.”

To capture the NASA contract, Boeing had to think ahead to assist the space agency in meeting its fiscal, scientific and human spaceflight goals in the next few years, said Mike Mott, NASA Systems vice president and general manager.

“One of Boeing’s strengths is understanding our customer,” Mott said. “That includes anticipating future requirements which enable them to fulfill their human spaceflight mission safely, efficiently and economically.”

Payload processing is trade jargon for making sure cargo and equipment aboard NASA space flights are ready to fly. Whether it’s a 45-foot long truss destined for the space station or a scientific experiment, it must be checked and readied for flight. That involves everything from testing to make sure the item works to actually fitting it inside the space shuttle’s payload bay or in the fairing of a rocket like a Boeing Delta II.

Boeing also processes all of the components destined for the International Space Station as well as NASA scientific probes such as Mars Odyssey and CONTOUR.

“We’ve developed a team with a lot of unique talents and skills,” Elbon said. “Whether it’s a clerk or an engineer, we all perform critical tasks that really aren’t done anywhere else in the world.”

The Boeing payload team works in facilities such as Kennedy Space Center’s Space Station Processing Facility and various on-site clean rooms for satellite processing. Specialized tools developed by the team include ones to load ISS supply modules and handle delicate scientific probes eventually sent far beyond the reach of human hands.

Elbon said one of the most key areas is working with and supporting the customer. In this case it’s NASA.

“I think Boeing and NASA’s enthusiasm for space exploration rubs off on each other,” he said. “Plus, Brevard County (Fla.) is a small community and we work and play together. I feel I really know and understand the people I’m supporting.”

About 550 Boeing employees process payloads at Kennedy Space Center, the adjacent Cape Canaveral Air Force Station, as well as Vandenberg Air Force Base, Calif. An additional 300 people are employed by nine subcontractors and partners: Alenia Spazio, All Points Logistics Inc., CMT Inc., Cimarron Software Services, Indyne Inc., PRHP, Spacehab Inc., Jacobs Engineering Group Inc. and Yang Enterprises.

Employees and subcontractors are adding to the Boeing legacy of having processed every space shuttle payload beginning with Columbia’s maiden flight in April 1981. Even with more than 100 shuttle flights worth of experience, the team continually refines its skills and methods.

Payload processing techniques have evolved through the years and the CAPPS contract targets those improvements along with commercialization activities. Boeing competed against other aerospace firms for the new contract.

“CAPPS dictated we do business differently than we did under the old contract,” said Jim Chilton, the Boeing Florida Operations mission management director. “Our contract team developed a leaner and more flexible operation.”

Part of that flexibility includes securing commercial customers for the Kennedy Space Center payload facilities and equipment. Boeing is funding a commercialization office to promote NASA facilities including the Operations and Checkout Building and four smaller payload processing facilities. The office is also working with real estate broker Trammell Crow Co. to represent the facilities and support equipment like a thermal vacuum chamber and an electromagnetic laboratory at Kennedy Space Center.

In addition, Boeing has formed a commercialization strategic alliance, which includes the Governor of Florida, Enterprise Florida, the Florida Space Authority, Boeing Realty, Boeing Capital Corp., Boeing Technology Services, and Boeing Enterprise Labs and Test Resources. In addition to securing commercial customers for payload assets, the commercialization office works closely with NASA in supporting the Science Experiment Research and Processing Laboratory (SERPL) and the International Space Research Park.