22 Sep 15
Update MRL Matrix to address
STE/SIE Validation
Steve Watts
AMRDEC
256-876-3244
Need for Validation
•
Inspection equipment planning, design, validation, and control have always been considered a critical element of a
contractor’s quality program. The AMRDEC’s Quality Engineering (QE) Division is working hard to improve the way STE/SIE
and acceptance test procedures associated with the hardware testing and buyoff is validated.
•
It is critical that "validation" efforts for STE/SIE be conducted during EMD and prior to LRIP to ensure the capability of test
sets to produce data that shows repeatability and accuracy of measurements and the capability to pass "good" hardware and
fail "bad" hardware. For example:
–
In the production world, contractor requirement interpretations, objectives, and influences affect the adequacy and quality
of ATE produced. So, it is entirely possible that a product passes when verified (contractor needs) but fails when
validated (government needs). This can happen when for example, a product is built per the specifications but the
specifications themselves fail to address the user’s needs. Case in point will be that the requirements might need
clarification and/or it is determined that there is a need for more testing.
•
An independent government validation of the contractor’s verification will ensure that the final acceptance test equipment and
procedures do not end up containing trivial problems such as operating procedures not being clear or incomplete (i.e. based
on tribal knowledge) to more serious problems such as a set of acceptance test requirements not being tested due to an
oversight or arbitrarily omitting a test requirement because it was deemed too expensive to accomplish. This alleviates the
risk of accepting bad hardware or rejecting good hardware in LRIP.
•
The bottom line is that the last line of defense that the Government has for assessing the condition of the hardware prior to
acceptance and one of the primary functions of government quality engineering is the ATE validation process. At the very
least, testing across government validated and controlled ATE will assure that the hardware design meets the most basic
performance requirements (under ambient conditions) and forms a basis for DD250 acceptance.
A Government validated and controlled ATE provides a proven method to evaluate and accept hardware;
Particularly when the test equipment used for hardware acceptance is the primary basis for DD250.
Approach
• Recommended approach through the Life-Cycle:
• Contractor develop an STE/SIE Validation Plan
• Government review/approve Validation Plan
• Contractor performs verification prior to government validation as part
of Pilot Line
• Contractor maintains Validation in Production
• Re-Validate as necessary throughout Production (i.e. any changes)
• Update the MRL Matrix to reflect the execution of this
recommended approach, and to specifically state the
terminology “Validation”.
Recommended Verbiage
Engineering and Manufacturing Development
MRL 7
Production and Deployment
MRL 8
MRL 9
MRL 10
Current Language
Tooling, test and inspection
equipment proven on pilot line
and additional requirments
H.1 - Tooling/Special - Production tooling and STE/SIE design and
identified for LRIP. Mfg
Test and Inspection development efforts are underway. Mfg Equipment equipment maintenance
Equipment (STE/SIE) maintenance strategy developed
demonstrated on pilot line.
- All tooling, test, and
inspection equipment
proven by LRIP and
additional requirements
identified for FRP. Mfg
equipment maintenance
schedule demonstrated.
- Proven tooling, test, and inspection equipment is in
place to support maximum FRP. Planned equipment
maintenance schedule achieved.
Recommended Changes
- Production tooling and STE/SIE design and
H.1 - Tooling/Special development efforts are underway and validation
Test and Inspection plans for STE/SIE are complete. Mfg Equipment
Equipment (STE/SIE) maintenance strategy developed.
All tooling, test, and
inspection equipment
Tooling, test and inspection
proven by LRIP and
equipment proven on pilot line additional requirements
and additional requirments
identified for FRP. Mfg
identified for LRIP. SIE/STE
equipment maintenance
validated as part of Pilot Line
schedule demonstrated.
Validation IAW approved
STE/SIE Validation
validation plan. Mfg equipment maintained as necessary.
maintenance demonstrated on Revalidations completed as
pilot line.
necessary.
Recommended changes are highlighted in RED
Proven tooling, test, and inspection equipment is in
place to support maximum FRP. Planned equipment
maintenance schedule achieved. STE/SIE Validation
maintained as necessary. Revalidation completed as
necessary.
Comments from MRL WG
Comments from MRL WG Meeting (7-28-15)
Comment
Explanation
Action
Take out "Government"
How does Val Plan relate to Test &
Insp Plan in Thread F.2
Take out the term "Government" to prevent
Term "Government" taken out of
confusion. In some cases, a prime contractor may
recommended changes
use this to evaluate a supplier.
The "Test & Insp" Plans apply to the product or end
item.
No change
The "Validation" Plan applies to the piece of test
equipment.
Is there a CDRL for Val Plan
Yes - DI-MISC-80759
No change
Update Users Guide
Update the Users Guide to elaborate on changes
incorporated in Matrix
Waiting for final determination
on Matrix changes
Summary
• AMRDEC’s Quality Engineering Division identified need and
provided approach & recommended changes to MRL Matrix
• MRL Working Group reviewed at 28 Jul 15 meeting and
provided comments
• Currently presenting approach & recommended changes to
Government/Industry Workshop for comments
• Will incorporate Workshop comments and present to MRL WG
for final determination