Attachment 5 - Sample FAT Plan.pdf

MK 706 Shipping Document FAT Plan i

01 Aug 2012

MK 706 MOD 0 SHIPPING CONTAINER

First Article Test Plan ii

CONTENTS

INTRODUCTION

1.1 DESCRIPTION

1.2 APPLICABLE DOCUMENTS

Standards Drawings

2.0 TEST OBJECTIVE

3.0 TEST ITEM CONFIGURATION

4.0 FIRST ARTICLE TEST MATRIX

5.0 TEST AND INSPECTION DESCRIPTION

5.1 VISUAL & DIMENSIONAL INSPECTION

5.2 FIT AND COMPATIBILITY TEST

5.3 LEAK TEST

5.4 REPETITIVE SHOCK TEST

5.5 FREE FALL DROP TEST

6.0 EXPECTED TEST RESULT

7.0 DATA COLLECTION, REDUCTION AND ANALYSIS

Introduction

1.1 Description

Roughly rectangular in shape, the MK 706 Container consists of four aluminum tubes with common end caps, each tube capable of holding a single MK 66 (2.75-inch) rocket motor. A single cover located in the top end cap allows access to all four tubes. The cover is secured with a combination quarter-turn/screw-type fastener, and features four circular rubber gaskets – one to seal each tube. The lateral surfaces of both end caps contain stacking lugs and matching recesses which allow stable horizontal tiering of like containers. Longitudinal restraint of the rocket motor in the tube is provided by polyethylene foam buffers (one each end) and acrylic disc spacers (on bottom, three top) which fit snugly against the end of the rocket motor, while two fiberboard strips taped about the circumference of the motor prevent contact with the tube wall.

The container measures 451/4” X 8” X 8” and weighs 20 pounds empty. This weight becomes 75 pounds when loaded with four 13 ½ pounds MK 66 Rocket Motors (including 4 acrylic spacers and 2 fiberboard strips per rocket motor).

1.2 Applicable Documents

Standards

MIL-STD-648D Department of Defense Design Criteria Standard Specialized Shipping Containers

Drawings

Number Revision Title

233AS601 J BODY ASSEMBLY

233AS602 E COVER ASSEMBLY

233AS603 D TOP

233AS604 G BASE

233AS605 C TUBE, BODY

233AS606 C SPIDER ASSEMBLY

233AS607 F BUFFER

233AS608 E SPACER

233AS609 F COVER PLATE

233AS610 F SHAFT ASSEMBLY

233AS611 E CLAMPING BAR ASSEMBLY

233AS612 D WASHER

233AS613 G WASHER

233AS614 D GASKET

233AS615 D SPIDER ASSEMBLY

233AS616 F RIVET

233AS617 F SHAFT

233AS618 F CLAMPING BAR

233AS619 E BUSHING

233AS620 D LUG

233AS621 C PIN

233AS622 D SHIPPING CONTAINER MARK 706 MOD 0

2.0 Test Objective

The objective of this test plan is to provide inspections and testing data to support First Article Testing (FAT) for the MK 706 MOD 0 Shipping Container in accordance with drawing 233AS622. The FAT is being performed to qualify the contractor for production of the MK 706 Mod 0 Shipping Container.

3.0 Test Item Configuration

There will be one (1) MK 706 MOD 0 Shipping Container, constructed in accordance with drawing 233AS622, being evaluated for FAT. Unless accompanied by a deviation, the one shipping container shall conform to the dimensional and material requirements of the MK 706 Mod 0 Shipping Container drawings specified in 1.2.

All Material Review Board (MRB) actions including Requests for Deviations (RFD’s) and Engineering Change Proposals (ECP’s) shall be completed prior to testing and documented in the final report. A detailed container pedigree including component serialization, quality control assessment, and inspection data and processing records shall be obtained and documented in the final test report.

4.0 First Article Test Matrix

Table 1. First Article Test Matrix

Inspection / Test Test Method Paragraph

Visual & Dimensional Inspection 5.1 A Fit and Compatibility Test 5.2 B Leak Test 5.3 C Repetitive Shock Test 5.4 D Free Fall Drop Test 5.5 E Leak Test 5.3 F

5.0 Test and Inspection Description

The tests and inspections to be performed are shown in the test matrix, section 4.0. The test and inspection specified are described in detail below:

5.1 Visual & Dimensional Inspection

The MK 706 container will be visually inspected for physical damage on the overall container and dimensionally inspected for conformance to drawing 233AS601 through 233AS622, as listed in 1.2. All

5.2 Fit and Compatibility Test

The container will be loaded with four inert MK 66 Rocket Motors, supplied by the Government, and evaluated for proper fit, compatibility, and ease of installation/removal.

5.3 Leak Test

The body assembly will be leak tested in accordance with note 9 of drawing 233AS601, Rev. J and the cover assembly will be leak tested in accordance with note 7 of drawing 233AS602, Rev. E. Each tube and the cover assembly will be submereged in water, pressurized to 5.00 psig for 15 seconds (minimum) and checked for leaks. No leakage is allowed.

5.4 Repetitive Shock Test

The container will be loaded with four inert MK 66 Rocket Motors, supplied by the Government, and subjected to the repetitive shock test of paragraph 5.5.2 of MIL-STD- 648D. The loaded container will be placed on a vibration platform and the platform vibrated with a 1 – inch double amplitude at a frequency of 4.1 Hz for a period of two hours. This input motion shall cause the container to leave the input platform by at least 1/16 inch on each cycle.

5.5 Free Fall Drop Test

The container will be loaded with four inert MK 66 Rocket Motors, supplied by the Government, and subjected to the free fall drop test of paragraph 5.2.3 of MIL-STD- 648D. Eight drops will be made from a height of 19 inches onto a concrete surface:

points of contact shall consist of two pairs of diagonally opposite corners, top, bottom, and two adjacent sides. The rocket motors and inert grains must remain undamaged and the container capable of continued use. Minor dents that do not affect stackability are acceptable.

6.0 Expected Test Result

The First Article Test Unit will not show any major physical damage and will not show any leakage.

Security

There are no security requirements for this validation as all activities are unclassified.

Location

First article testing will take place at the Contractor’s facility. No Government test facilities will be used in this validation.

Participation

Government and Contractor participation roles and responsibilities are identified in Table 2. The Government is invited to witness all test activities The Government shall be given a minimum of 7 business days notification, email is acceptable, prior to the scheduled FAT date which includes production of the FAT samples.

Table 2. FAT Roles and Responsibilities

Government Contractor Roles • Test team member

• Review/approve test plan

• Test conductor

• Submit formal test plan Responsibilities • Review test data

• Review/approve test report

• Collect test data

• Conduct data reduction/analysis

• Provide test report

7.0 Data Collection, Reduction and Analysis

Actual Test and Inspection data records (actual recorded data) used shall be included within the report. The data records shall be signed and dated by the inspector that performed the test or inspection at the time of the test. Actual signed data records may be supplemented with, but not replaced by, electronic spreadsheets to allow for data reduction. Transposed records should be avoided as a substitute for the original data sheet. All materials required by the drawings, 1.2, shall be validated by inclusion of a certificate of compliance (CoC) in the FAT report. Each CoC shall include any and all objective data necessary to evaluate material conformance to listed specifications and requirements.