Sunshield tear problem and the squid jig

Scott Willoughby, Vice President of Program Excellence at Northrop Grumman and former program manager for the James Webb Space Telescope, joined Jamie Flinchbaugh to share insights on leading one of the most complex systems ever built. With 35 years at Northrop Grumman, a NASA Distinguished Public Service Medal, and membership in the National Academy of Engineering, and we have to include a degree from Lehigh University. Scott brought deep wisdom about managing massive programs where failure simply isn't an option.

Managing the James Webb Space Telescope meant dealing with a system seven times larger than Hubble that had to operate at minus 400 degrees Fahrenheit, a million miles from Earth. Scott explained that tackling such complexity requires breaking problems down through systems engineering, but with a critical twist: don't trust yourself. Everything on Webb was done in twos. NASA and Northrop Grumman each built independent models, particularly for thermal and dynamic performance. When pointing a telescope at light from 13.5 billion years ago, stability matters, and even small temperature changes cause mechanical components to shrink and expand. The two teams challenged each other constantly, ensuring they reached the same conclusions before moving forward.

When models disagreed, which happened often during iteration, teams had to get intimately familiar not just with their own work but with how the other side modeled things. Sometimes, differences came down to using different densities or levels of detail. Other times, teams discovered they were working from different versions of test data. Scott emphasized that much of technical work is about getting people to communicate, to say their assumptions out loud rather than keeping them in folders or inside their heads.

Creating a learning culture among world-class engineers and PhDs required leading by example. Scott realized early that being a leader didn't mean knowing everything. He deliberately asked questions that seemed obvious, sometimes the wrong questions, to get beneath the surface. He echoed back what others said in his own words, creating what he called a safe zone in the middle of dialogue where you don't have to be right until the end. By showing vulnerability and modeling openness, he encouraged teams to converge on solutions without anyone feeling accused of being wrong.

Testing followed a crawl, walk, run philosophy. Scott stressed taking the hardest punch as early and as low in the system as possible. They qualified components by subjecting them to extremes beyond predicted conditions, building margin into designs for things they couldn't model perfectly. The hardest day in any satellite's life is usually day one, which for Webb lasted six months as systems were deployed and activated for the first time.

One of Scott's favorite stories captured the power of listening to everyone. When membrane tears appeared during sunshield deployment testing, engineers wrestled with an apparently intractable problem. The solution came from a technician who suggested using something like a squid jig from his fishing tackle box to align the 107 pin holes through multiple membrane layers gently. His compliant device solved one of the program's most complicated problems. Scott learned that elegant solutions sometimes come from understanding how things get built, not just how they're designed.

For transparency with stakeholders, Scott developed a rhythm of meeting every three months to discuss what had happened since the last time, what they were doing now, and most importantly, what challenges lay ahead. By forecasting risks before they materialized, discussing backup plans, and building anticipation for difficult tests, he made it easier to discuss both failures and successes. What advice would he offer to anyone stepping into similar roles? Take a deep breath, realize it won't go perfectly, and talk to others who've been there. Growth doesn't occur without discomfort, and leaders get measured not by perfection but by how they respond to adversity.

Learn more about Scott's work at https://www.northropgrumman.com/, https://science.nasa.gov/mission/webb/, and https://www.imdb.com/name/nm12283488/. Connect with Scott on LinkedIn.