In one example, early tests resulted in some of the booster rocket's O-rings burning a third of the way through. These O-rings provided the gas-tight seal needed between the vertically stacked cylindrical sections that made up the solid fuel booster. NASA managers recorded this result as demonstrating that the O-rings had a "safety factor" of 3. Feynman incredulously explains the magnitude of this error: a "safety factor" refers to the practice of building an object to be capable of withstanding more force than it will conceivably be subjected. To paraphrase Feynman's example, if engineers built a bridge that could bear 3,000 pounds without any damage, even though it was never expected to bear more than 1,000 pounds in practice, the safety factor would be 3. If, however, a 1,000 pound truck drove across the bridge and it cracked at all, even just a third of the way through a beam, the safety factor is now zero: the bridge is defective.
Feynman was clearly disturbed by the fact that NASA management not only misunderstood this concept, but in fact inverted it by using a term denoting an extra level of safety to describe a part that was actually defective and unsafe. Feynman continued to investigate the lack of communication between NASA's management and its engineers, and was struck by management's claim that the risk of catastrophic malfunction on the shuttle was 1 in 105; i.e., 1 in 100,000. Feynman immediately realized that this claim was risible on its face; as he described, this assessment of risk would entail that NASA could expect to launch a shuttle every day for the next 274 years while suffering, on average, only one accident. Investigating the claim further, Feynman discovered that the 1 in 105 figure was stating what they claimed that the failure rate ought to be, given that it was a manned vehicle, and working backwards to generate the failure rate of components.
I wanted to reach through the television and strangle him.
