Military Qualification Process

nullMilitary Qualification ProcessMilitary Qualification ProcessOutlineOutlineMIL Acquisition Process EMC Process Environmental Stress & Reliability Information sourcesnullRange of Military Equipment Range of ConsiderationsRange of ConsiderationsFunctional and Operational Requirements Information Technology Logistics NBC Environmental Stresses & RAM EMC & Spectrum Management Complex Electromagnetic EnvironmentComplex Electromagnetic EnvironmentNew technology Global Information Grid (GIG) Future Combat System (FCS) Counter IED High Power Microwave (HPM) & Directed Energy Weapons Active Denial SystemnullSource: DoD RAM GuideFOTE= Follow-On Test and Evaluation OT= Operational Test IOTE= Initial Operational Test and Evaluation DT/OT =Development Test/Operational TestLUT= Limited User Test FOT= Follow-on Test IOT= Initial Operational TestnullWhere Does the Process Start?Where Does the Process Start?nullIdeas and initial concepts from defense companies, government laboratories, academia, etc. Military and Political LeadershipDoD 5000DoD 5000Defense Acquisition Framework DOD 5000.1, 5000.2 Navy SEC NAV INST 5000.2CArmy Acquisition Procedures 70-3nullTEMP SOW CDRLSolicitations & ContractsMDA= Milestone Decision Authority PM= Program ManagerSolicitations & ContractsTEMP= Test & Evaluation Master Plan SOW= Statement of Work CDRL= Contractor Data Requirements ListPrime Contractor Subcontractors DoD 5000 Acquisition FrameworkE3 & Spectrum Support CommandsE3 & Spectrum Support CommandsAcquisition Support and Test Facilities NAVAIR- Naval Air Systems Command Naval Air Warfare Center Aircraft Division, Lakehurst New Jersey, Patuxent River Maryland. Naval Air Warfare Center Weapons Division, China Lake & Point Mugu California NAVSEA-Naval Sea Systems Command Naval Surface Warfare Center, Dahlgren Division (NSWCDD) Naval Undersea Warfare Center Newport (NUWC Newport) SPAWAR Space and Naval Warfare Systems Command SPAWAR Systems Center San Diego (SSC SD) ATEC- Army Test and Evaluation Command Redstone Test and Technical Center White Sands Missile Range Aberdeen Proving Grounds Ft. Huachuca Electronic Proving Ground (EPG) TACOM- Tank Automotive Command JSC- Joint Spectrum Centernull7.6.3.11. Spectrum Supportability and Electromagnetic Environmental Effects (E3) Control Requirements in the Statement of Work (SOW) . DoD 5000 Guide BookMIL-HDBK-237 6.6.3.3 Statement of Work (SOW) The SOW sample wording addressing the E3/SS area that might be included in a contract for a system follows: “The contractor shall design, develop, integrate, and qualify the system such that it meets the E3/SS performance requirements of the system specification. The contractor shall perform analyses, studies, and testing to establish E3/SS controls and features to be implemented in the design of the item. The contractor shall perform inspections, analyses, and tests, as necessary, to verify that the system meets its E3/SS performance requirements. The contractor shall prepare and update the DD Form 1494 throughout the development of the system for spectrum-dependent equipment and shall perform analysis and testing to characterize the equipment, where necessary. The contractor shall establish and support an E3/SS WIPT to accomplish these tasks. MIL-HDBK-237 may be used for guidance.”Contract Data Requirements ListContract Data Requirements ListData Item Requirements for Spectrum Supportability and Electromagnetic Environmental Effects (E3) Control Requirements in the Contract Data Requirements List (CDRL) The following are examples of data item requirements typically called out for spectrum supportability and E3 control requirements in the CDRL: DI-EMCS-80199B EMI [Electromagnetic Interference] Control Procedures DI-EMCS-80201B EMI Test Procedures DI-EMCS-80200B EMI Test Report DI-EMCS-81540 E3 Integration and Analysis Report DI-EMCS-81541 E3 Verification Procedures DI-EMCS-81542 E3 Verification Report DI-MISC-81174 Frequency Allocation Data Test and Evaluation Master PlanTest and Evaluation Master PlanOperational Testing Communications and Interoperability Testing EMC Testing Environmental Stress and RAM Testing E3 Requirements E3 Requirements Program Manager Develops the TEMP Command support personnel identify contract requirements Platform & Ordnance Requirements are set MIL-STD-464 ADS-37A-PRF Flow down Equipment & Subsystems Requirements MIL-STD-461MIL-STD-464A MIL-STD-464A Radiated Immunity Lightning EMP nullnullWhole Platform TestingWhole Platform TestingArmy- White Sands Missile Range Army- Aberdeen Proving Grounds Navy- Patuxent River Air Force- Eglin Air Force Base nullnullMIL-STD-464A MIL-STD-464A 5.6 Subsystems and equipment electromagnetic interference (EMI). Individual subsystems and equipment shall meet interference control requirements (such as the conducted emissions, radiated emissions, conducted susceptibility, and radiated susceptibility requirements of MILSTD-461) so that the overall system complies with all applicable requirements of this standard. Compliance shall be verified by tests that are consistent with the individual requirement (such as testing in accordance with MIL-STD-461).MIL-STD-461EMIL-STD-461ECE - Conducted Emissions CS - Conducted Susceptibility RE - Radiated Emissions RS - Radiated SusceptibilityEquipment and Subsystems Requirements from MIL-STD-461E Equipment and Subsystems Requirements from MIL-STD-461E Sec 5. TABLE V. Requirement matrix.Equipment and Subsystems Requirements from MIL-STD-461E Equipment and Subsystems Requirements from MIL-STD-461E Sec 5. TABLE V. Requirement matrix.Conducted RF EmissionsConducted RF EmissionsConducted Transient SusceptibilityConducted Transient SusceptibilityConducted RF SusceptibilityConducted RF SusceptibilityRadiated EmissionsRadiated EmissionsRadiated SusceptibilityRadiated SusceptibilityShipboard DCShipboard DCMIL-STD-1399 DC Magnetic Field Environment. Shipboard AC Power Quality & Surges Lightning Requirements & TestingLightning Requirements & TestingPrimarily Follow RTCA DO-160E Direct Effects Secondary Effects Power Systems RequirementsPower Systems RequirementsMIL-STD-1399MIL-STD-704Vehicle Power RequirementsVehicle Power Requirements 28VDC Electrical Systems Surges Spikes Ripple Transient EmissionsMIL-STD-1275Automotive RequirementsAutomotive Requirements12VDC Vehicle Conducted Transient Test SAE J1113, ISO 7637 Load Dump Inductive Switching 12VDC Electrical Systems Tests Alternator Ripple Voltage variations Dips, Drops, Reverse Polarity Electrostatic Discharge12VDC Electrical Systems nullNon-Military Tailoring ProcessGMW 3097 July 2006nullMIL-STD 461 CS 114GMW 3097 BCInullGMW 3097 RIMIL-STD 461 RS 103Environmental Conditions and ReliabilityEnvironmental Conditions and ReliabilityEnvironmental Test and Evaluation Master Plan (ETEMP) Life Cycle Environmental Profile (LCEP) Operational Environment Documentation (OCD) Environmental Issues Criteria List (ECIL) Contract Requirements Statement of WorknullnullnullnullEnvironmental Test Program Tailoring ProcessnullFailure MechanismsTime Dependent Cumulative Damage – When continued use exceed the endurance limit. Example: Fatigue, Aging, Corrosion, WearOverstress Damage- A single excursion exceeds strength500 Low Pressure (Altitude) 502 Low Temperature 504 Contamination by Fluids 506 Rain 511 Explosive Atmosphere 512 Immersion 513 Acceleration 516 Shock 517 Pyroshock 521 Icing/Freezing Rain 522 Ballistic Shock501 High Temperature 503 Temperature Shock 505 Solar Radiation 507 Humidity 508 Fungus 509 Salt Fog 510 Sand and Dust 514 Vibration 515 Acoustic Noise 518 Acidic Atmosphere 519 Gunfire Vibration 520 Temp Humidity, Vibe, Alt 523 Vibro-Acoustic TemperaturenullMIL-STD-810F NOTE: Tailoring is essential. Select methods, procedures, and parameter levels based on the tailoring process described in Part One, paragraph 4.2.2, and Appendix C. Apply the general guidelines for laboratory test methods described in Part One, paragraph 5 of this standard.Tailoring Is Essential Vibration Vibration Environmental TailoringEnvironmental TailoringnullnullC.13.34 Reliability and Maintainability (R&M) Program Requirements. C.13.34.1 Reliability. The objective Reliability point estimate for the Repower kit is 20,000 Mean Miles Between Hardware Mission Failure (MMBHMF). The objective Engine durability (i.e. component replacement or overhaul) is 200,000 miles. The system shall demonstrate a 0.5 probability at 50% confidence that the powertrain (i.e. engine, transmission, t-case, and differentials) will operate without a durability (i.e. component replacement or overhaul) failure for 20,000 miles.Reliability MetricnullReliability MetricsRAM DefinedRAM DefinedR- Reliability is the probability of an item to perform a required function under stated conditions for a specified period of time. A- Availability is a measure of the degree to which an item is in an operable state and can be committed at the start of a mission when the mission is called for at an unknown (random) point in time. Availability as measured by the user is a function of how often failures occur and corrective maintenance is required, how often preventative maintenance is performed, how quickly indicated failures can be isolated and repaired, how quickly preventive maintenance tasks can be performed, and how long logistics support delays contribute to down time. M- Maintainability is the ability of an item to be retained in, or restored to, a specified condition when maintenance is performed by personnel having specified skill levels, using prescribed procedures and resources, at each prescribed level of maintenance and repair. System ReliabilitySystem ReliabilityEngine 98.61Fuel Delivery 95.10Steering 99.10Transmission 93.50Static Reliability R= (95.10) * (98.61) * (93.50) * (99.10) = 86.89System ReliabilitySystem ReliabilityQuantifying Reliability Quantifying Reliability Analysis of Field Data Measure performance of test item Evaluate similarity of similar devices Accelerated Testing Based on operational data Test to Failure Weibull Analysis Success-Run Testing Vibration Life ProfileVibration Life ProfileReliability Demonstration using Success Run TestingReliability Demonstration using Success Run TestingEstablish Life Requirement Vibration life; based on vehicle characteristics at location 100,000 miles Success Run Equation Determine sample size, reliability, and confidence. Develop Test Acceleration Factors TAF= (G accelerated / G normal) m = ( T normal / T accelerated) nullSuccess Run Equation N= ln(1-C) ln(R) Ex. R=.97, C=0.5, N=23Vibration Test Acceleration FactorVibration Test Acceleration Factorm = Material Fatigue Constant: 6.4 for aluminum leads1 in electronic assemblies, 5 for an overall usage value 10. 4 for connector fatigue or fretting Corrosion1 problems, 3.3 for highly accelerated vibration for metal fatigue (greater than 3X original stress). Source: GMW 3172nullReliability ProcessesReliability ProcessesC.25 RELIABILITY, AVAILABILITY, MAINTAINABILITY (RAM) PROGRAM C.25.1 The Contractor shall maintain a comprehensive RAM program to ensure that the MMPV meets the RAM standards set forth in the performance specification. The design shall be monitored throughout the entire period of performance to identify and assess any changes, which would impact RAM. The Contractor shall develop reliability analysis and predictions as required to ensure compliance with the performance specification. The program shall encompass all aspects of reliability with respect to design selection of components, predictions, and testing. If is determined that an item is a throwaway, an analysis shall be performed at the next higher indenture level. The Contractor shall maintain and make available to the Government all RAM data on any vendor or subcontractor supplied item and shall inform the Government of any part or component which will degrade system RAM requirements. The RAM program shall minimally include the following: C.25.1.1 Procedures and Controls: The Contractor shall maintain procedures and controls, which ensure products, obtained from suppliers, vendors and subcontractors meet reliability requirements. The Contractor shall (a) establish, implement, and maintain documented procedures, which detect and/or preclude the use of substandard or counterfeit parts in the production process, and impose similar requirements on subcontractors; and (b) Provide the Government with reasonable notice of any special RAM program review meetings scheduled with subcontractors so Government representatives may attend at their discretion. C.25.1.2 Reliability Predictions: The Contractor shall provide detailed design reliability predictions based on a defined configuration and associated models. The predictions shall be allocated down to the lowest indenture level and updated each time significant design or mission profile changes significantly impact the MMPV or any of its subsystems. The reliability modeling method shall mathematically relate the reliability block diagrams of the MMPV to time-event relationships. These tasks shall be performed in consideration of the end-user operational environment including sun load thermal, shock and vibrations.Why systems fail to achieve RAM requirements: Why systems fail to achieve RAM requirements: Poorly defined or unrealistically high RAM requirements. Lack of Priority for Achieving RAM Too little engineering for RAM. Among engineering process failures, these stand out: - Failure to design-in reliability early in the development process. - Inadequate lower level testing at component or subcomponent level. - Reliance on predictions instead of conducting engineering design analysis. - Failure to perform engineering analyses of commercial-off-the-shelf (COTS) equipment. - Lack of reliability improvement incentives. - Inadequate planning for reliability. - Ineffective implementation of Reliability Tasks in improving reliability. - Failure to give adequate priority to the importance of Integrated Diagnostics (ID) design influence on overall maintainability attributes, mission readiness, maintenance concept design, and associated LCC support concepts. - Unanticipated complex software integration issues affecting all aspects of RAM. - Lack of adequate ID maturation efforts during system integration. Failure to anticipate design integration problems where COTS and/or increment design approaches influence RAM performance. Source: DoD Guide to Achieving RAMnullSources of InformationSources of InformationDoD-5000.1, DoD-5000.2 MIL-STD 461E, 464A, 810F MIL-HDBKs MIL-HDBK-235, 237D MIL-HDBK-338, DoD Guide for Achieving RAM MIL-HDBK-189, 781 AETP Series NATO Documents Global Engineering Documents GMW 3097 & GMW 3172 SAE J1455, ISO 16750Sources of InformationSources of Informationhttp://assist.daps.dla.mil/quicksearch/https://akss.dau.milhttp://www.nato.int/docu/standard.htmnullSummary: Qualification process is tailored from start to finish Military is incorporating RAM requirements Can rely on MIL and Non-MIL information to build test plans Questions on the Process Thank you.