F_16_Boresight_System_PD_7_Aug_2025_ATT3.docx

INCH-POUND

PD24WRWNZEC004

7 August 2025

PURCHASE DESCRIPTION

F-16 BORESIGHT SYSTEM

1. SCOPE

1.1 Scope. The boresight system is a system that is used to perform confidence check and boresighting to a Head-Up Display (HUD), Gun, Inertial Navigational Unit (INU), Radar antenna, and other aircraft sub-systems for all the blocks of the F-16 aircraft. The boresight system consists of a measurement system and aircraft-specific fixtures that attach to specific aircraft alignment points already established by the aircraft manufacturer on the aircraft.

2. APPLICABLE DOCUMENTS

2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE STANDARDS

(Copies of these documents are available online at https://quicksearch.dla.mil/.)

2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications of the exact revision level shown form a part of this document to the extent specified herein.

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION (NASA)

SP-20205003605 Technology Readiness Assessment Best Practices Guide (Application for copies should be addressed to NASA, 300 Hidden Figures Way SW, Washington, D.C. 20546, https://ntrs.nasa.gov/.)

2.3 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AEROSPACE INDUSTRIES ASSOCIATION (AIA) / NATIONAL AEROSPACE STANDARD (NAS)

NASM24667 Screw, Cap, Socket Head, Flat Countersunk, 82°, Alloy Steel, UNC-3A (Application for copies should be addressed to Aerospace Industries of Association of America, Inc., 1000 Wilson Blvd., Arlington VA 22209, http://www.aia-aerospace.org/.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) INTERNATIONAL

B18.3 Socket Cap, Shoulder, Set Screws, and Hex Keys (Inch Series) (Application for copies should be addressed to ASME International, Two Park Ave., New York NY 10016, http://www.asme.org/.)

ASTM INTERNATIONAL (ASTM)

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken PA 19428-2959, http://www.astm.org/.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code (Application for copies should be addressed to NFPA, 1 Batterymarch Park, Quincy MA 02169, http://www.nfpa.org/.)

SAE INTERNATIONAL

(Application for copies should be addressed to SAE International Customer Service, 400 Commonwealth Drive, Warrendale PA 15096, http://www.sae.org/.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), two samples shall be subjected to first article inspection in accordance with 4.2.

3.2 Description and general layout.

3.2.1 Measurement instruments. The boresight system shall be completely digital; analog instruments shall not be provided. The boresight system shall perform all calculations without the intervention of the operator. Measurement instruments shall be protected against drops during typical handling and operational conditions. Measurement instruments shall provide fluid/contaminate resistance in accordance with 3.17.6.

3.2.2 Fixtures. The contractor shall furnish complete F-16 aircraft boresight fixtures, as detailed and necessary for mounting on the different sub-system of the aircraft. The boresight system shall include aircraft-specific fixtures that attach to specific alignment points already established on the aircraft. No aircraft modification shall be allowed. Fixtures shall include all associated hardware necessary for proper performance of the boresight system.

3.3 Performance.

3.3.1 Confidence check. The boresight system shall verify whether a sub-system is aligned within tolerances.

3.3.1.1 Aircraft boresight reference line (ABRL). The boresight system shall be designed to use ABRL. ABRL measurement shall be displayed on the screen.

3.3.1.2 Sub-system measurement. The boresight system shall identify and display the sub-system measurements.

3.3.1.3 Error calculation. The boresight system shall calculate and display the difference between ABRL and sub-system measurements. Error shall be compared with the tolerances of each sub-system to determine whether the sub-system is properly aligned.

3.3.2 Boresighting. The boresight system shall enable alignment of a sub-system that has been identified out of tolerance or misaligned.

3.3.2.1 Real time feedback measurement. The boresight system shall provide the operator real time feedback of the measurements. The boresight system shall tell when the sub-system is aligned.

3.3.3 Angular measurements. The boresight system shall have the capability to support angular pitch, roll, and yaw measurements. The system shall provide a reference in three axes – elevation (pitch), azimuth (yaw), and roll, with respect to the ABRL.

3.3.4 Measurement units. The system shall be capable of changing measurement units. Measurement units shall be in degrees (°), minutes (’), seconds (”).

3.3.5 Support equipment verification check/self-check. The boresight system shall be able to verify serviceability and accuracy before start using the boresight system in the aircraft. Measurements shall be displayed in degrees (°), minutes (’), and seconds (”).

3.3.6 Aircraft sub-systems and tolerances. The boresight system shall perform confidence check and boresighting of the following sub-systems: Fire Control Radar (FCR) antenna, Heads-Up-Display (HUD), Gun system, Rate Sensor Unit (RSU), Embedded Global Positioning System/Inertial Navigation Unit (EGI/INU), Left and Right Angle-of-Attack (AOA), and Left and Right hard points. Sub-system tolerance TABLE I shall be used to determine whether or not the sub-system is aligned.

TABLE I. F-16 aircraft boresight tolerances.

(RSU Only For block 25, 30, 32(C).

Gun System

Gun vertical and horizontal boresight points fall within 14.25 ±2.00 minutes below horizontal and 5.50 ±2.00 minutes right of vertical reference

3.3.7 Aircraft initial conditions. The boresight system shall be used in hangar conditions including, but not limited to hanger doors open, indirect sun, and Aerospace Ground Equipment (AGE) running around the hanger. Also, the boresight system shall be used on a typical hangar floor. The boresight system shall perform under the following input condition:

a. Centerline fuel tank may be removed from the aircraft.

b. Wind velocity shall be 10 knots or less.

c. The aircraft shall not require jacking, leveling, or repositioning before using the boresight system.

d. Centerline ECM pod may be removed from the aircraft.

e. All aircraft equipment weighing 15 pounds or more forward of fuselage station 160.00 (face of inlet) shall be installed or replaced with ballast (except as noted) while establishing ABRL and determining aircraft pitch and roll reference angles.

f. All access doors and panels of the aircraft shall be closed/installed (except those require to be opened or removed to install boresight fixtures) unless otherwise specified.

g. The boresight system shall perform properly whether or not there is fuel in the aircraft.

h. The boresight system shall perform whether or not the engine is installed in the aircraft.

i. No personnel shall be aboard aircraft during boresighting procedures, except to adjust the HUD pedestal.

j. No movement in aircraft pitch, roll, or yaw shall occur.

3.3.8 Operators. The system shall require no more than three operators to boresight the aircraft.

3.3.9 Power requirement. The boresight system shall operate on 100 - 240VAC, at 50 or 60 Hz.

3.3.10 Weight and dimensions. The dimensions and weight of the boresight system kit shall be as small as practicable consistent with the performance requirements specified herein. The boresight system kit shall not exceed usable space and limits of a 463L pallet.

TABLE II. Maximum weight and dimensions.

3.3.11 Boresight system cases. The boresight system kit shall come with carrying cases. Each case shall be a hard-shell case with foam insert with appropriately sized and shaped cutouts to hold each required item; the case with its inserts shall protect the contents from any damage during normal handling and transportation. The cases shall be equipped with handles for two-person lifting. Boresight system cases shall provide fluid/contaminate resistance in accordance with 3.17.6.

3.3.12 Labeling. A two-person lift label shall be clearly marked on each case of the boresight system kit if the weight of the case exceeds 50 pounds.

3.4 Calibration.

3.4.1 Calibration cycle and location. The boresight system shall maintain a calibration cycle no less than 24 months. The boresight system shall be designed to be calibrated by regional Precision Measurement Equipment Laboratories (PMEL) within the Government. The boresight system components that need calibration cycles shall have a label attached with the calibration expiration date.

3.4.2 Calibration tool. The contractor shall provide whatever special tools are necessary to calibrate the boresight system. When specified (see 6.2), a special tools kit shall be provided with the boresight system. Calibration tool shall be designed to be used in the PMEL within the Government.

3.4.3 Calibration certificate. Each boresight system shall be supplied with an initial certificate of calibration. Calibration shall be traceable to the International System of Units through National Institute of Standards and Technology (NIST) or other internationally recognized testing laboratory.

3.4.4 Shock indicator. Fixtures shall have a shock indicator to indicate whether the fixture requires calibration.

3.5 Software.

3.5.1 Operating system. The operating system software of the boresight system shall be a supportable version of Windows, Linux, or other similar operating system software fully compatible with system hardware.

3.5.2 Data storage and parameters. The software of the boresight system shall store aircraft boresight results in the computer. Parameters such as operator’s name, aircraft tail number, and date/time shall be stored with the data. The boresight system shall have the capability to export and import calibration data on the computer/controller. The boresight system shall have the capability to export and import boresight procedure data to/from file. The boresight system shall have the capability to support report output to a printer.

3.5.3 Software restoration. The boresight system software shall be capable of being restored from Computer Program Identification Number (CPIN) software by field users.

3.5.4 User interface. The user interface shall be a Graphical User Interface (GUI) with appropriate buttons and menu options to fully operate and calibrate the system.

3.5.5 Software alignment/adjustment. Fixtures shall be calibrated using software alignment/adjustment to make offset corrections. Associated software shall be provided.

3.6 Computer hardware. The computer hardware shall be fully supported by the manufacturer and be compatible with system software and other hardware devices.

3.7 Cybersecurity. The boresight system shall be designed with cybersecurity considerations in accordance with DODI 8500.01, DODI 8510.01, and AFI 17-101 along with referenced security controls for applicable Information Technology (IT) and/or Operational Technology (OT), commonly referred to as Platform Information Technology (PIT), and all associated software and/or firmware. The boresight system shall implement all applicable security controls from National Institute of Standards and Technology (NIST) Special Publication (SP) 800-53 as allocated through the IT categorization and control selection process of Risk Management Framework (RMF).

3.7.1 Operational software. Any operating or system software, application software, and/or controller firmware shall, at a minimum, implement the following technical security controls to the maximum extent practical:

a. Configured in accordance with the appropriate Defense Information Systems Agency (DISA) Security Technical Implementation Guide (STIG) as applicable.

b. Restrict actions from being performed without user identification and authentication, except for those actions necessary to ensure safety and prevent mishaps.

c. Configured to disable ports, protocols, and services which are not required for the system to perform its expected functions and mission.

d. Capable of verifying integrity of application software and/or firmware prior to installation or operational use.

e. Software shall not have any high-level vulnerabilities as reported in the National Institute of Standards and Technology (NIST) National Vulnerability Database (https://nvd.nist.gov/vuln) concerning Common Vulnerability and Exposures (CVEs).

3.7.2 Access control. Logical access to the boresight system shall be through Role-Based Access Control (RBAC) with roles and permissions established for user access and operation of the system based on mission requirements. User accounts shall employ the best practice of least privilege access, with only permissions assigned necessary to perform the functions of that assigned role (that is, Administrator, Calibration Technician, Boresight User). Passwords shall not be documented in technical manuals/instructions except in the case of default, one-time use passwords which must be changed by a user for that level of user account. Administrative level passwords shall not be included in technical manuals/instructions.

3.7.3 Antivirus capability. The boresight system shall include antivirus/anti-malware scanning capability that can be updated and kept current by field users without elevated permissions.

3.7.4 External/removeable media. The boresight system shall include the capability to read/write to external/removeable media (such as CD/DVD-RW drive/disk). USB thumb drives shall not be used.

3.7.5 Backup and recovery. The boresight system shall have the ability by field users to back up/export any configuration/calibration data required to restore the system in the event of hardware failure or software corruption. The boresight system shall have the ability by field users to back up/export any boresight/airframe data generated by the system. This data can be used for archival purposes or for recovery to a new system in the event of hardware failure or software corruption.

3.8 Environmental requirements.

3.8.1 Operating temperature range. The boresight system shall be capable of performing confidence check and boresighting in ambient temperatures ranging from 35º F to 120º F.

3.8.2 Storage temperature range. The boresight system shall be capable of storage in ambient temperatures ranging from -30º F to 160º F.

3.8.3 Humidity. The boresight system shall be capable of operation and storage from 5 to 95% (±5%) relative humidity, including conditions where condensation takes place in the form of water and/or frost.

3.9 Explosive atmosphere. The boresight system shall be in accordance with the explosive atmosphere requirement of MIL-STD-810 method 511.7 Procedure I.

3.10 Transportability. The boresight system shall be transportable on aircraft, truck or trailer, railcar, and ship and shall be capable of withstanding the mechanical shock, vibration, temperature, humidity, and pressure characteristics of these modes of transportation.

3.11 Electromagnetic interference (EMI). The boresight system shall be in accordance with the following radiated emission and susceptibility requirements of MIL-STD-461: RE102 and RS103.

3.12 Human engineering. The boresight system shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including but not limited to the use of Mission-Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

3.13 Safety

3.13.1 System safety. The design of the boresight system shall not contain any system safety mishap risk categories greater than medium as defined in MIL-STD-882.

3.13.2 Hazardous materials. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases. The boresight system shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. Class I ODS and hazardous materials shall not be used in any system, component, or process. The boresight system shall not contain or use either hexavalent chromium or cadmium. Class I and Class II ODS are defined in 40CFR82.

3.13.3 Component protection. The boresight system shall be designed so that all electrical/mechanical output components are enclosed and access is not required during normal operation. Further, the boresight system shall be designed to safely permit access to internal components that may be required during troubleshooting for failures or other special needs. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All wires and cables shall be supported and protected to minimize chafing and abrasion. Grommets shall be provided wherever wires or cables pass through bulkheads, partitions, or structural members.

3.14 Protective coating, finish, and corrosion control.

3.14.1 Corrosion control. The boresight system shall be constructed of parts and materials that are corrosion and deterioration resistant, or coated to resist corrosion and deterioration, in accordance with MIL-STD-1568.

3.14.2 Finish. The exterior finish color of the boresight system is at the contractor’s discretion; fixtures shall be Lusterless Red, Color Number 31136 of SAE AMS-STD-595. Anything that attaches to aircraft shall have a remove before flight tag.

3.15 Markings. All external devices which require an operational or maintenance interface (that is, cautions, warning, etc.) shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible but shall not be less than one-half inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of SAE AMS-STD-595, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of SAE AMS-STD-595.

3.16 Identification and information plates.

3.16.1 Identification plate. The boresight system shall be provided with a permanently-marked identification data plate constructed of a non-corroding metal permanently affixed to the exterior of the boresight system in a readily accessible location in accordance with MIL-STD-130. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer's name, Commercial and Government Entity (CAGE), date of warranty expiration, contract number, and National Stock Number (NSN). In addition, the identification plate shall include six (6) blank lines across the bottom for future etching by the USAF. The identification plate shall be mounted at a conspicuous place on the exterior of the boresight system.

3.16.2 Unique Identification (UID). The boresight system and any of its components for which the Government's unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings and contain the following information:

a. National Stock Number (NSN).

b. Manufacturer's part number.

c. Serial number.

d. Manufacturer's CAGE.

3.17 Design and construction. The design shall promote cost effective, life-cycle sustainability by addressing considerations such as incorporating open standards while satisfying system performance requirements. It shall be designed and constructed so that no parts will work loose in service, and to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. It shall be weatherproof and designed to prevent the intrusion of water, sand, and dust into critical operating components.

3.17.1 Recycled, recovered, environmentally preferable, or biobased materials. Recycled, recovered, environmentally preferable, or biobased materials shall be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.17.2 Mechanical design.

3.17.2.1 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial (see 6.3.1) components. When applicable, fasteners shall be installed with the application of a design fastening torque such that an adequate preload is introduced in the fastener to prevent losing or fatiguing the fasteners. Externally threaded fasteners for use with internally threaded nuts or holes shall be in accordance with SAE J429. Internally threaded nuts shall be in accordance with SAE J995. Tapped threads shall have a minimum thread engagement in accordance with Table III. To the maximum extent possible, fastening designs that utilize bolted connections shall be accomplished using a through-bolt method, and secured with locking nuts or weld-nuts. The use of riv-nuts and tapped threads is discouraged. The use of socket-head, flat, countersunk fasteners shall be minimized. When used, socket-head, flat, countersunk fasteners shall be in accordance with NASM 24667, or ASME B18.3 and ASTM F835, and shall be used with a corresponding nut in lieu of a threaded hole to alleviate potential fastener/hole misalignment and bending stress on the head. When in contact with aluminum materials, steel fasteners shall be coated with a Zinc/Aluminum Corrosion Protective Coating in accordance with ASTM F1136 Grade 3.

TABLE III. Minimum thread engagement.

Material

Minimum Thread Engagement

3.17.3 Wiring. All wires used in the boresight system shall be multi-stranded copper conductor, flame retardant, moisture, heat, and oil resistant in accordance with NFPA 70. Cables and wiring shall provide fluid/contaminate resistance in accordance with 3.17.6. Cables and wiring shall be protected from breakage by providing strain relief so that the weight of a connector, or a cable assembly and connector, does not damage the boresight system or the aircraft. Wires, wire runs, and wiring harnesses shall be placed, bundled, and positioned so that access to other components is not inhibited or impeded. Any tying or lacing used to bundle individual wires into harnesses shall be of sufficient strength to hold the wires in position without crimping, slicing, or otherwise damaging wire insulation or strands. Wires, wire runs, and wiring harnesses shall be supported to retain position and provide support from stretching or sagging.

3.17.3.1 Wire marking. All wires shall be numbered for easy identification. The marking shall be permanently applied to the wire to withstand all specified operating conditions herein throughout the life expectancy of the end item. Marking shall be applied within 3 inches of each end and at intervals not to exceed 12 inches throughout the wire length. Wires having a total length of less than 18 inches shall be marked within 3 inches of both ends and once in the (approximate) middle of the wire. The wire-numbering scheme shall be consistent with that currently being employed by industry standards. Wires energized from the battery (except the battery cables) shall be marked using red characters. All other wires shall be marked using black characters. The use of colored wire coating as a marking scheme is prohibited.

3.17.3.2 Plugs and connectors. Weatherproof, sealed, O-ring connectors shall be used to the maximum extent possible to join wires and wiring harnesses and prevent the intrusion of water, sand, dust, condensation, salt fog, etc. into wiring connections. The use of military specification (MS) type plugs and receptacles is also encouraged. The use of terminal strips and ring or forked style crimp on connections for wire terminations shall be minimized. Unused openings in the plugs, receptacles, switches, or other similar wiring and control devices shall be sealed. Individual wires and wire runs within a wiring harness shall be the full length of the harness and not spliced together. The use of crimp-on 'piggyback' style splices used to join one or more wires together is prohibited.

3.17.4 Foreign Object Damage (FOD). Metal, rubber, and plastic tags, covers, or plugs commonly affixed to commercial items (see 6.3.1) during the manufacturing process shall be removed from the boresight system to prevent FOD hazards. All loose metal parts, such as pins, connector covers, caps, etc. shall be securely attached to the boresight system with wire ropes or chains. "Dog tag" style beaded chains shall not be provided. Removable panels, if provided, shall be attached with captive fasteners.

3.17.5 Error-proof design. The design of the boresight system shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be designed to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.17.6 Fluid/contaminate resistance. The boresight system cases, measurement instruments, cables, and wires shall provide protection against water, jet fuel, engine oil, synthetic lubricating oils, and hydraulic fluid found in and around the aircraft and engine as well as foreign objects, that is, dirt, dust, and sand found in hangar environments or in a storage environment.

3.18 Technology Readiness Level (TRL). The boresight system shall have a TRL of at least 6 in accordance with NASA SP-20205003605.

3.19 Workmanship. The boresight system, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.19.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.19.2 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.19.3 Cleaning. The boresight system shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspection. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Operational inspection (see 4.3).

c. Conformance inspection (see 4.4).

Requirements shall be verified in accordance with Table IV.

Table IV. Requirement verification matrix.

4.2 First article inspection. The first article boresight system shall be subjected to the analyses, demonstrations, examinations, and tests described in 4.6.1 through 4.6.11. The contractor shall provide or arrange for all test equipment and facilities, except for the compatibility test described in 4.6.3. Unless otherwise approved by the procuring activity, all first article boresight system shall be in the same configuration at all times and configuration changes shall not be made during the first article inspection.

4.3 Operational inspection. All operational inspection shall be satisfactorily completed and approved prior to final first article acceptance.

4.4 Conformance inspection. Each production boresight system shall be subjected to the examination described in 4.6.1

4.5 Inspection requirements.

4.5.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.5.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data and/or shorter intervals shall be provided as appropriate for any specific test. The contractor shall submit the resulting test report for Government approval.

4.5.3 Test rejection criteria. Throughout all tests specified herein, the boresight system shall be closely observed for the following conditions, which shall be cause for rejection:

4.5.4 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all potential failures that occur during the first article and operational tests. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions. The contractor shall establish and maintain a FRACAS database; all information shall be entered into the database. Authorized procuring activity personnel shall have read-only access to the FRACAS database.

4.5.4.1 Problem and failure action. At the occurrence of a problem or potential failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test, with minimum interruption to the other test samples continuing test.

4.5.4.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or potential failure of the contractor hardware or software or Government furnished equipment (GFE). The report shall contain the information required to permit determination of the origin and correction of the failure. The contractor's existing failure report form may be used with minimum changes necessary to conform to the requirements of this specification. The failure report form shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at the time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair actions taken to return the test sample to operational readiness.

c. Information describing the results of the investigation, the analysis of all part failures, an analysis of the system design, and the corrective action taken to prevent failure recurrence. If no corrective action is taken, the rationale for this decision shall be recorded.

4.5.4.1.2 Identification and control of failed items. A failure tag shall be affixed to the failed part immediately upon the detection of any failure or suspected failure. The failure tag shall provide space for the failure report serial number and for other pertinent entries from the test sample failure record. All failed parts shall be marked conspicuously or tagged and controlled to ensure disposal in accordance with contract requirements. Failed parts shall not be handled in any manner which may obliterate facts which might be pertinent to the analysis. Failed parts shall be stored pending disposition by the authorized approval agency of the failure analysis.

4.5.4.1.3 Problem and failure investigations. An investigation and analysis of each reported failure shall be performed. Investigation and analysis shall be conducted to the level of hardware or software necessary to identify causes, mechanisms, and potential effects of the failure. Any applicable method (for example, test, microscopic analysis, applications study, dissection, X-ray analysis, spectrographic analysis) of investigation and analysis which may be needed to determine failure cause shall be used. When the removed part is not defective or the cause of failure is external to the part, the analysis shall be extended to include the circuit, higher hardware assembly, test procedures, and subsystem if necessary. Investigation and analysis of GFE failures shall be limited to verifying that the GFE failure was not the result of the contractor's hardware, software, or procedures. This determination shall be documented for notification of the procuring activity.

4.5.4.1.4 Failure verification. Reported failures shall be verified as actual failures or an acceptable explanation provided to the procuring activity for lack of failure verification. Failure verification is determined either by repeating the failure mode of the reported part or by physical or electrical evidence of failure (for example, leakage residue or damaged hardware). Lack of failure verification, by itself, is not sufficient rationale to conclude the absence of a failure.

4.5.4.1.5 Corrective action. When the cause of failure has been determined, a corrective action shall be developed to eliminate or reduce the recurrence of the failure. Repairs shall be made in accordance with normal field operating procedures and manuals. The procuring activity shall review the corrective actions at the scheduled test status review prior to implementation. In all cases the failure analysis and the resulting corrective actions shall be documented.

4.5.4.1.6 Problem and failure tracking and closeout. The closed loop failure reporting system shall include provisions for tracking problems, failures, analyses, and corrective actions. Status of corrective actions for all problems and failures shall be reviewed at scheduled test status reviews. Problem and failure closeout shall be reviewed to assure their adequacy.

4.6 Test methods.

4.6.1 Examination of product. Each boresight system shall be examined to verify compliance with the requirements herein prior to accomplishing any other demonstrations or tests listed in 4.6. A contractor-generated, Government-approved checklist (part of the test procedure) shall be used to identify each requirement not verified by an analysis, certification, demonstration, or test, and shall be used to document the examination results. Particular attention shall be given to materials, workmanship, dimensions, surface finishes, protective coatings and sealants and their application, fastening, and markings. Proper operation of each boresight system function shall be verified. Each production of the boresight system shall be inspected to a Government-approved reduced version of the checklist.

a. 3.3.11 Contractor certification that the boresight system complies with the requirements of 3.3.11

b. 3.12 Contractor certification that the boresight system complies with the human engineering requirement.

c. 3.13 Contractor certification that the boresight system complies with the safety requirements of 3.13.

d. 3.14 Contractor certification that the boresight system complies with protective coating, finish, and corrosion control requirements of 3.14.

e. 3.15 Contractor certification that the boresight system complies with markings requirements of 3.15.

f. 3.16 Contractor certification that the boresight system complies with identification and information plates requirements of 3.16.

g. 3.17 Contractor certification that the boresight system complies requirements of 3.17.

h. 3.19 Contractor certification that the boresight system complies with the requirements of 3.19.

4.6.2 Performance tests.

4.6.2.1 Confidence check and boresighting test. The boresight system shall perform confidence check and boresighting to demonstrate compliance with all applicable requirements of 3.2.1, 3.2.2, 3.3.1, 3.3.1.1, 3.3.1.2, 3.3.1.3, 3.3.2, 3.3.2.1, 3.3.3, 3.3.4, 3.3.5, and 3.3.6. Confidence check and boresighting test shall be tested in all blocks of the F-16 aircraft.

4.6.2.2 Calibration tool testing. The calibration tool shall be tested to demonstrated that the boresight system can be calibrated in the PMEL lab. Test shall demonstrate compliance with all applicable requirements of 3.4.2, 3.4.4, and 3.5.5.

4.6.3 Compatibility test. The boresight system fixtures shall be installed on the respective aircraft for a fit-check. Fixtures shall be tested in all blocks of the F-16 aircraft. The boresight system shall then perform confidence check and boresighting to demonstrate compliance with 4.6.2.1.

4.6.4 Calibration cycle analysis. A calibration cycle analysis shall be conducted to demonstrate compliance with requirement 3.4.1.

4.6.5 Weight and dimension tests.

4.6.5.1 Weight test. The weight of a first article boresight system shall be measured to demonstrate compliance with the weight requirement of 3.3.10.

4.6.5.2 Dimension measurement. A first article boresight system shall be measured to demonstrate compliance with the dimensional requirements of 3.3.10.

4.6.6 Cybersecurity verification. All requirements identified in paragraph 3.7, to include all subparagraphs, shall be verified and validated by a combination of test, demonstration, and inspection and analysis. All technical security controls shall be tested and/or demonstrated along with examination of results to verify proper implementation. All procedural security controls shall be verified by inspection and analysis.

4.6.7 Environmental testing.

4.6.7.1 Low temperature storage and operation test. A first article boresight system shall be tested in accordance with MIL-STD-810, Method 502.7, Procedures I and II, to demonstrate compliance with the low temperature storage and operating requirements of 3.8.1 and 3.8.2. Test duration shall be one 24-hour cycle for each procedure beginning no less than two hours after test item temperature stabilization.

4.6.7.2 High temperature storage and operation test. A first article boresight system shall be tested in accordance with MIL-STD-810, Method 501.7, Procedures I and II, to demonstrate compliance with the high temperature storage and operating requirements of 3.8.1 and 3.8.2. Test duration shall be one 24-hour cycle for each procedure beginning no less than two hours after test item temperature stabilization.

4.6.7.3 Humidity test. A first article boresight system shall be tested in accordance with MIL-STD-810, Method 507.6, Procedure Ib, to demonstrate compliance with 3.8.3.

4.6.8 Explosive atmosphere test. A first article boresight system shall be tested in accordance with MIL-STD-810 method 511.7 Procedure I to demonstrate compliance with 3.9

4.6.9 Transportability verification. An engineering analysis shall be performed to demonstrate compliance with 3.10.

4.6.10 Electromagnetic interference test. A first article boresight system shall be tested in accordance with MIL-STD-461: RE 102 and RS 103 to demonstrate compliance with 3.11.

4.6.11 System safety hazard analysis. A system safety hazard analysis of the boresight system shall be conducted in accordance with 4.3.1 through 4.3.8 of MIL-STD-882 to demonstrate compliance with the mishap risk requirement of 3.12.1.

5. PACKAGING

5.1 For…