ASCWII_Det_3_OI_99-103_-_Marked_Up02102012.pdf

BY ORDER OF THE COMMANDER ASC/WII DET 3 INSTRUCTION 99-103

MEDIUM ALTITUDE UAS DIVISION DETACHMENT 3(ASC/WII/Det 3) 10 February 2012

INTELLIGENCE, SURVEILLANCE, RECONNAISANCE AND SPECIAL OPERATIONS FORCES

DIRECTORATE (ISR&SOF or ASC/WI)

AERONAUTICAL SYSTEMS CENTER (AFMC)

WRIGHT-PATTERSON AIR FORCE BASE (WPAFB) OH 45433-7106

Test and Evaluation

TEST AND EVALUATION PROCESS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

NOTICE: This publication is available digitally on the ASC/WII SharePoint web page at https://cs.eis.afmc.af.mil/sites/predreap/default.aspx. If you lack access, contact your Publishing Distribution Office or the ASC/WI helpdesk at DSN 785-5843 or on the web at https://303portal.wpafb.af.mil/.

Office of Primary Responsibility: ASC/WII/ Det 3 Chief of Test (ASC/WII/Det 3/ CT)

Certified by: ASC/WII/ Det 3 Commander (ASC/WII/Det 3 CC) Pages: 17

Distribution: X

This instruction implements AFMC Policy Directive 99-1. This publication outlines the flight test and evaluation (T&E) policy for ASC/WII and applies to all personnel participating in flight test within ASC/WII and its locations at WPAFB OH, Detachment (Det) 3 in Poway CA, Operating Location (OL) Gray Butte CA and any other deployed or temporary locations, such as Creech Air Force Base NV or Naval Air Warfare Center, China Lake CA.

SUMMARY OF REVISIONS

This instruction supersedes 658 AESSI 99-103, 30 Nov 2006. The document was revised to update the change in unit designation and to reference the current Memorandum of Agreement (MOA) between ASC/WI and 412 TW and the addition of ASC/WII as alternate for developing and implementing test policy. It reflects the latest changes that apply to ASC/WII from the Air Force (AF), Major Command (MAJCOM) and Center Test Authority directives and instructions, as well as changes resulting from Department of Defense 5000 series and the Office of the Secretary of Defense, Acquisition, Technology and Logistics realignment.

1. Scope. This instruction defines the roles and responsibilities of primary ASC/WII T&E personnel and the ISR&SOF Test Representative (TestRep), with respect to program T&E. It establishes procedures for preparing test and safety plans, conducting technical, safety and test readiness reviews and executing flight test activity.

1.1. References:

1.1.1. AFPD 99-1, Test and Evaluation Process

1.1.2. AFI 99-103, Capabilities Based Test and Evaluation

1.1.3. AFMCPD 99-1, Test Management

1.1.4. ASCI 99-103, Test and Evaluation Management

1.1.5. 303 AESWI 99-103, Test and Evaluation Process

1.1.6. AFMCI 21-126, Temporary (T2) Modification of Aerospace Vehicles

1.1.7. AFMCP 91-1, Flight Safety and Technical Considerations Guide for Flight Testing

1.1.8. AFI 91-202, AFMC Sup 1, Chapter 13, Test and Safety Review Process

1.1.9. AACI 91-201, AAC Test Safety Review Process

1.1.10. AFFTC-TIH-93-01, Air Force Flight Test Center (AFFTC) Test Plan Preparation Guide

1.1.11. AFFTC-TIH-88-002, Writing AFFTC Technical Reports

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1.1.12. AFFTCI 91-105, AFFTC Test Safety Review Process

2. Responsibilities. The ASC/WI Directorate was designated the Responsible Test Organization (RTO) for MQ-1 and MQ-9 programs by the Deputy, Air Force Program Executive Office (AFPEO) /AFMC on 06 Oct 06.

Accordingly, the ASC/WI 99-103 directs that oversight of day-to-day T&E flight test activity will normally reside within the organizations executing flight test as an RTO. As RTO, ASC/WI has designated ASC/WII to conduct ground and flight test operations in accordance with (IAW) AF, MAJCOM, center, wing and group instructions.

The primary ASC/WII T&E responsibilities are as follows:

2.1. ASC/WII Division Chief or ASC/WII Deputy Division Chief. The ASC/WII/Div Chief will: 1) Develop and direct policy and procedures to maintain special projects’ T&E capability; 2) Approve each medium risk test and safety plan by signing the Test Project Safety Review (TPSR); 3) Coordinate with ISR&SOF/Director for approval of each high risk test; 4) Approve and coordinate each medium risk (or higher) test sortie IAW Air Force Test Center MOA.

2.2. ASC/WI TestRep. As provided, the TestRep will: 1) Provide T&E oversight of all MQ-1 and MQ-9 test activities IAW AF and MAJCOM policies; 2) Evaluate all test requirements from PMs, engineers and customers; 3) Participate in all phases of the acquisition cycle to include, among other duties, integrated test teams (ITT), test integrated product teams (TIPT), system safety groups, configuration control boards (CCB), product improvement working groups, technical review boards (TRB), safety review boards (SRB), test planning and reporting and aircraft certifications; 4) Assess the validity of all Det 3 test requirements and provide test execution options to test and PMs; 5) Make preliminary assessment of technical and safety risks and coordinate final risk assessment/approval for all planned T&E activities; 6) Review all test plans and test reports; 7) Serve as TRB chairman when requested by the Det 3 Chief of Test and 8) Serve as SRB chairman when requested by the Det 3 Chief of Test Safety.

2.3. ASC/WII, Detachment 3 Commander. With regard to T&E activity, the Det 3 CC will: 1) As the flying unit commander oversees all aspects of T&E flight operations, test safety and test aircraft configuration control;

2) Ensure test plan approval and flight operations are conducted IAW the current MOA between ASC/WII and the MAJCOM-assigned Operations Group (OG), currently 412 OG and 3) Ensure proper level of T&E oversight and participation during all T&E activity.

2.4. ASC/WII, Operating Location-Detachment 3 Commander. The OL-Det 3 CC will: 1) Supervise all flying operations under tactical control of the Det; 2) Approve low risk test cards; 3) Ensure that appropriately reviewed and approved test plans are effectively transitioned to ground/flight test operations; 4) Ensure participating aircrew members meet all T&E qualification requirements; 5) Provide aircrew training and other expertise as required to support the full spectrum of Det T&E requirements; 6) Coordinate external assistance for flight crew support as necessary; 7) Assure effective flight crew briefings and debriefings are conducted for all T&E missions and 8) Coordinate with emergency support organizations for aircraft emergency and crash/rescue efforts unique to test operations and locations.

2.5. Detachment Chief of Test Safety. Appointed by ASC/WII/Det 3 CC, the Det 3 Chief of Test Safety will:

1) Oversee the safety portion of all Det 3 flight test and evaluation; 2) Ensure safety reviews are conducted and documented as appropriate for the final risk level and IAW this supplement and the current MOA between ASC/WII and the MAJCOM-assigned OG and 3) Serve as the SRB chairman or request assistance from the TestRep or others designated by ASC/WII’s Det 3/CC to serve as SRB chairman.

2.6. Detachment Chief of Test. The Chief of Test (CT) and deputies will be appointed by ASC/WII Det 3 CC. The CT is directly responsible to the Det 3 commander for all AFMC MQ-1 and MQ-9 ground and flight activities. In addition to the duties of ASC/WII Det 3 99-103, the CT will: 1) Manage test schedule and priorities for all AFMC test activities; 2) Approve minor, in-scope revisions of the test plan; 3) Assist the Test Director (TD) with coordination activities and test resources during testing; 4) Be responsible for all aspects of the test process and is the single focal point for T&E in the Det; 5) Act as primary interface between the Det and the TestRep; 6) Assist with the development and approval of all test plans; 7) Ensure a technical review is completed and documented as appropriate for the anticipated level of risk; 8) Serve as the TRB chairman or designate others to serve as the TRB chairman; 9) Provide T&E expertise and guidance on test-related issues;

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10) Ensure the test file is complete; 11) Ensure completion of the test kickoff and test readiness review (TRR) IAW this instruction and 12) Ensure an appropriate/trained test director is designated for each T&E mission.

2.7. Project Engineer. The Project Engineer (PE) is a government representative responsible for cradle-to-grave test management and execution of a specific project. The PE will: 1) Ensure that all test-related paperwork is completed in time to meet the project schedule; 2) Work with General Atomics Aeronautical Systems, Inc (GA-ASI) personnel, the CT and the TD to execute test portions of the project; 3) Ensure the test package is complete; 4) Disseminate quicklook reports to team members not on normal distribution and 5) If the PE is a qualified TD and wants to perform those duties for their project they can.

2.8. Test Director. Each test project will be assigned a lead TD. The TD is responsible to the CT and PE for all required steps to complete their assigned test program. They can be government, GA-ASI or outside agency personnel who have completed the required TD training and are properly qualified. The TD is part of the aircrew and will: 1) Be responsible for the efficient and safe conduct of their assigned test points IAW an approved test package; 2) Brief the mission as part of the pre-flight briefing; 3) Ensure all resources required for testing are ready for testing; 4) Complete the Test Readiness Review Checklist and brief at the Test Readiness Review to the CT or designee; 5) Be responsible for having a complete test package that covers all aspects of their test program and 6) Maintain the test file with help from the PE.

2.9. Detachment 3 Chief of Product Assurance. The Det 3 Chief of Product Assurance (PA) will: 1) Ensure that maintenance and production concerns are addressed throughout all phases of T&E; 2) Attend (or designate representatives to attend) all TRBs and SRBs and ensure appropriate review of all test plans and reports and 3) Approve and coordinate all installation procedures and final PA/Quality Assurance(QA) inspection for aircraft test temporary 2 (T-2) modifications.

2.10. Pilot in Command. The Pilot in Command (PIC) will: 1) Have the ultimate responsibility for the safe operation of the aircraft and 2) Have the authority to terminate any test point they feel is unsafe.

2.11. Project Pilot/Sensor Operator. Each test project will be assigned a project pilot and/or project Sensor Operator (SO). The project pilot/SO will: 1) Be responsible for providing inputs to and coordination of the test plan, test cards and any test point(s) requiring non-routine maneuvering, 2) Participate in test planning, test conduct and test reporting including comments in TD quicklooks, 3) Participate in system SIL simulations, CETs and design reviews, etc as required to successfully get to completion of the test project.

3. Test Procedures. The Integrated Test Team (ITT) supersedes the test plan working group with expanded responsibilities (see AFI 99-103). Program managers should establish an ITT as early as possible in the acquisition cycle to address all T&E efforts. Every flight test plan will have a Test Project Safety Review (TPSR). Every ground test will have a TPSR if significant safety issues are present per the CT. The following requirements apply to all projects, whether primary or ride-along. A quick reaction capability program may customize this process to meet required timelines and require approval of ASC/WII. The customized process will focus on delivering a combat capability in a safe manner, while preserving an appropriate level of T&E oversight.

3.1. Test Schedule. A flight test schedule will be maintained with sufficient lead time and detail to allow timely coordination and to properly plan resources required for testing. The Det 3 Chief of Test and/or test project manager/engineer will ensure PMs are aware of actual or potential schedule issues.

3.2. Test Plan. The Det Chief of Test is the primary focal point for the completion of written test plans.

Guidance for preparing test plans is contained in the “Air Force Flight Test Center Test Plan Preparation Guide” (AFFTC-TIH-93-01). Contractor test plan format is acceptable, provided that it meets the intent of appropriate government T&E oversight. AFMC Pamphlet 91-1, “Flight Safety and Technical Considerations Guide for Flight Testing” includes information required by AFFTC TIH-93-01. The TD will work with the PE to ensure all appropriate personnel and agencies are involved in test planning. This will include any long lead resources and the agencies that control them. The TD will organize TIPTs as required. Multiple TDs can work a single package, with each being responsible for an assigned part of the test package. Contractor format may be used for test plans, but they must adequately answer the testing questions of AFFTCI 99-1 Attachment 2 appropriate to the complexity of the testing. This will result in test plans as short as one page or as long as necessary for complicated tests (i.e., new sensor and weapon integration).

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3.3. Technical Review. All test plans, contractor or government provided, will be reviewed as necessary while being written to gain input from subject matter experts. All test plans will have an independent technical review. As a minimum, the Chief of Test or TestRep will review all test plans. The TestRep may delegate this to a technically qualified individual or require others to review the plan as necessary to provide an independent review. The recommendation to hold a formal TRB will be made by the Det Chief of Test and approved by the TestRep. The determination to convene a formal TRB should consider test complexity, experience with similar tests, operator experience and the degree of required aircraft/weapon system modification; however, all medium and high risk tests require a TRB. Formal TRBs and SRBs may be combined for low risk test plans; however, the two reviews will remain conceptually independent. The TRB will always precede the SRB and have a separate chairman.

3.3.1. TRB Members. The chairman will be a project-independent, technically qualified individual.

Usually, the Det CT will chair the TRB, but the position may be elevated to the ASC/WII Chief Engineer, the TestRep or another technically qualified individual approved by Det CT. Required board members are the Det test project manager/engineer and flight operations and Det engineering and division engineer.

Representation from PA/QA is also highly encouraged. Others that should attend include participating test organization (PTO) representatives and appropriate contractor representatives. The TestRep and an engineering representative, or their designated representative, will participate via telecon or in person.

3.3.2. Technical Review Board Conduct. Elements that should be reviewed during a TRB include program objective, test purpose, test objectives, test conduct/method, measures of performance, success criteria, evaluation criteria, operational limitations, technical go/no-go criteria, limiting factors, test article configuration, results of previous tests, technical risk level and test reporting. If necessary, a page-by-page review of the test plan will be made.

3.3.3. Technical Review Board Documentation. After a TRB is held, the test engineer will publish minutes that include significant comments, concerns and action items with responses. The minutes will be maintained in the Det test file. The TRB chairman will endorse the technical adequacy of the test plan and assign an overall technical risk. These requirements will be can be documented on the TRB minutes (with the TRB chairman signature), in a separate Memo for Record (MFR) (with the TRB chairman signature) or on the TPSR or equivalent. If a formal TRB is not held, technical adequacy should be documented in a separate MFR (with the TRB chairman signature) or on the TPSR Form or equivalent (see Attachment 1).

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Table 3.3.4 Technical Risk Levels.

Subjective Risk Level

Description

LOW Hardware/software components are a mature progression of previous baseline/block design. Aircraft modifications require minimal aircraft instrumentation and/or have little or no impacts to basic aircraft/system controllability/performance. The contractor and ASC/WII Det 3 have experience modifying this type of aircraft/system (or similar). The number of planned sorties and/or the test schedule is adequate for meeting the test objectives. Aircraft certification plans have been established and the number of uncertainties has been minimized.

MEDIUM Hardware/software components are less mature with significant progression/ development (i.e., there is a large step forward in construction/materials or design/logic to achieve the next level of capability). Aircraft modifications require significant instrumentation and/or may impact basic aircraft/system controllability/performance. The contractor and ASC/WII Det 3 have little experience modifying this type of aircraft/system and associated with other MEDIUM risk criteria. Test objectives are defined and achievable, but adjustments are anticipated or may be required during the course of test. The number of planned sorties and/or the test schedule is aggressive and/or significant contingencies may preclude satisfying test objectives. Aircraft certification requirements are understood, but there may be some additions that emerge later. This is more than a normal baseline progression.

HIGH Hardware/software components are of a new design and/or not previously tested/ proven. Aircraft modifications require significant instrumentation and will impact basic aircraft/system controllability/performance. The contractor and ASC/WII Det 3 have no experience modifying this type of aircraft/system and associated with other HIGH risk criteria. Test objectives are not well-defined and/or unknown adjustments need to be made during the course of test.

The number of planned sorties and/or the test schedule is extremely aggressive and/or significant contingencies are anticipated. Aircraft certification requirements are not fully understood and the certification process may significantly impact/alter the test schedule and/or program requirements.

3.4. Test Approval. All test plans will be approved by government signature. Test plan approval will parallel TPSR approval and will depend on both the technical and safety risk level associated with the plan. Technical risk level for the test plan will be determined by the TRB Chairman. In the absence of additional guidance, low risk test plans will be approved by the Det commander, medium risk test plans will be approved by the ASC/WII Div Chief and info copied to the ASC/WI Director and high risk test plans will be approved by the ASC/WI Director and info copied to the ASC/CC. The approval signature will be documented on the test plan or a separate cover letter as necessary. The final test plan approval will be accomplished after the technical review and is separate from the TPSR signature.

3.5. Test Amendments. Minor, in-scope revisions to the test plan may be approved by the Det Chief of Test and Det/CC. These changes will be annotated on the primary copy of the test plan maintained in the Det.

Major, out-of-scope changes will be approved in the same manner as initial test plans. Any test plan changes with actual or potential safety implications or any changes due to a significant unexpected occurrence will require an amended TPSR or an equivalent or separate MFR documenting the changes and the additional risk assessment.

3.6. Safety Plan. A safety plan will be developed. The safety plan will identify specific test hazards, apply appropriate risk mitigation procedures and assign an overall level of safety risk. The TPSR serves to summarize the safety plan and risk assessment and establish the minimum required documentation. Every flight test plan will have a TPSR. Every ground test will have a TPSR if significant safety issues are present per the CT.

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3.6.1. Safety Review Board. The recommendation to conduct a formal SRB will be made by the Det Chief of Test Safety and approved by the Det commander and the TestRep. The determination to convene a formal SRB should consider test complexity, experience with similar tests, operator experience/training, the degree of required aircraft/weapon system modification and specific test hazards. Formal TRBs and SRBs may be combined for low risk test plans; however, the two reviews will remain conceptually independent. The TRB will always precede the SRB and have a separate chairman. If a formal SRB is not conducted, see Attachment 1 for proper documentation procedures.

3.6.1.1. Safety Review Board Members. The Chief of Test Safety will normally chair the SRB. The Chief of Test Safety may designate the TestRep or appointed Det 3 UTSO to chair the SRB. Required board members are a Det flight operations representative, a Det engineering representative and a Det PA representative. The Det PE must attend, unless waived by the chairperson. Others that should attend include PTO representatives and appropriate contractor representatives. When possible, the TestRep and an engineering representative will participate via telecon or in person.

3.6.1.2. Safety Review Board Conduct. The SRB board members will review the test plan to ensure test-unique hazards are identified, eliminated, minimized or controlled to an acceptable level and that the overall risk level is established. Mandatory discussion items include test aircrew procedures, test safety go/no-go items, the TPSR and the Test Hazard Analyses (THA). All supporting analyses (aerodynamic, structural, electrical loads and weight and balance) will be available at the SRB, and their results will be briefed when describing the test article. An overall safety risk will be assigned by the SRB chairman.

3.6.2. Safety Review Documentation. All safety reviews, formal or informal, will be documented using the TPSR Form or equivalent. If a formal SRB is held, a preliminary TPSR Form or equivalent should be completed prior to the SRB, but the final form will not be signed until after the conclusion of the SRB. If a formal SRB is not conducted, see Attachment 1 for proper documentation. Specific details for completing the TPSR Form or equivalent may be found in Attachment 1.

3.6.2.1. Test Project Safety Review Form or Equivalent Required Signatures. Section III will also list the safety signature approval authority (see safety approval paragraph 3.8). Signature of the approval authority is required prior to test execution.

3.6.2.2. Test Hazard Analysis. A THA will be conducted IAW AFI 91-202 AFMC Sup1 paragraphs

13.5.5.1 and 13.12 to identify any unique test hazards and to direct appropriate actions to mitigate the hazard. If test-unique hazards exist, they will be documented using the TPSR Form or equivalent. A sample THA can be found in Attachment 2. These THAs will be referenced in section IV, paragraph 7 of the TPSR Form or equivalent and are mandatory attachments to that form.

3.7. Safety Risk Level. The safety risk level will be determined IAW AFFTCI 91-105, AFFTC Test Safety Review Process. The hazard category and probability will be annotated in the appropriate block of the THA.

The overall test safety risk level will be the highest of the individual THAs or as determined by the SRB chair.

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3.8. Safety Plan Approval. All safety plans will be approved by government signature. Safety plan approval will parallel the technical test plan approval and depend on the level of risk associated with the plan. Risk level for the safety plan will be determined by the SRB. In the absence of additional guidance, low risk test plans will be approved by the Det commander, medium risk test plans will be approved by the ASC/WII Div Chief and info copied to the ASC/WI Director and high risk test plans will be approved by the ASC/WI Director and info copied to the ASC/CC. The approval signature will be documented on the TPSR Form or equivalent.

Risk Level Test/Safety Plan Approval

Test Card Approval

Info Copy

Low Det 3/CC OL-Det 3/CC

Medium ASC/WII Div Cheif

Det 3/CC 412 OG

High ASC/WI Director ASC/WII Div Cheif

412 OG

3.9. Safety Plan Amendments. Document amendments to the safety plan using the TPSR Form. Describe the nature of the changes in the appropriate paragraphs. If there is no change, state “no change” for the applicable paragraph. Number the amendments consecutively (i.e., 1, 2, 3) and annotate the date of the amendment on the original TPSR Form or equivalent. The amended TPSR Form or equivalent must be reviewed and signed by all participants and approved at least at the same level as the original TPSR. Amendments are required for:

Revisions to the test plan that affect the safety plan

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Significant unexpected occurrences, to include damage to the test article or support equipment, exceeding a safety of test limit or unfavorable departure from predicted results

Overly restrictive controls or proposed reduction in risk level Test hazards not previously identified or adequately controlled

3.10. Safety Plan Revisions. Any changes to the safety plan will be documented on an amended TPSR Form or equivalent. Complete only those sections of the TPSR Form where there is new or changed information.

3.11. Test Readiness Review. A TRR is required for all test projects. In addition to the requirements of ASC/WII I99-103, the TD (or multiple TDs for the project) will brief the TRR to the CT to ensure testing is ready to commence or continue into the next phase. The entire Test Package Binder will be reviewed for completeness at the TRR for both a formal and informal review. Specific software change requests and modification paperwork (AF 1067 or T-2 folder) for the next phase of testing will be reviewed to ensure they meet the scope of testing to be performed. Known software and hardware anomalies and watch items specific to the next phase will be reviewed. If these items contain significant information, the CT will require a formal review.

3.11.1. Members. The Det Chief of Test is responsible for ensuring all items on the TRR checklist are completed prior to flight test. The approval authority or designee will chair the TRR and/or complete the TRR checklist. If available, original SRB members will be included in the TRR. The Det Chief of Test will ensure that the TRR checklist is complete, that all action items have been closed and that the final documentation is maintained in the test file.

3.11.2. Conduct. Depending upon the type and complexity of the test, the TRR may be held as a formal board or completed by simply filling out the TRR checklist. Low risk test plans will complete a formal TRR at the discretion of the Det Chief of Test, unless mandated during the TRB or SRB. All medium and high risk plans will conduct a formal TRR.

3.11.3. Documentation. The TRR checklist will be completed prior to flight and filed in the test file.

Attachment 3 provides a template for the TRR. The Det 3/CC may delegate TRR approval authority for low risk test projects to the Chief of Test or the OL-Det 3 CC. An authorized TRR is required to commence testing.

3.12. Test Execution. The scope of test execution normally consists of the sortie (test sortie) execution approval, test card management (design, approval and changes) and the general conduct/coordination required to complete the test plan. For any test points performed there will be a TD assigned. For non-complex testing, the aircrew can act as TD if they have completed TD training. Whenever test points are being performed, either the CT or a deputy will be assigned for all test activity, and the duties as CT will be his/her primary activity for that day. The CT does not need to be present at the flight test facility (although that is preferred) but will be available by phone at a moments notice. Because CT duties are primary, aircrew can not act as CT when assigned to an active mission. Once the CT or deputy is assigned responsibility for testing that day, that individual should remain responsible for the entire day to prevent confusion.

3.12.1. Sortie Approval. Test Sortie Approval will be completed IAW the MOA between ASC WI and 412 TW. An informational copy of all Medium or High Risk Safety Packages will be sent to the 412 OG upon approval. Copies of Med Risk Test Cards will be available to the 412 OG/CC the day prior to the scheduled sortie. Copies of High Risk Test Cards will be available to the 412 OG/CC, 412 TW/CC and AFMC/A3 the day prior to the scheduled sortie.

3.12.2. Test cards. The TD is responsible for test card creation and creation of a test configuration sheet.

The purpose of test cards is to provide step-by-step procedures for the objectives in the test plan. Test card formats are flexible depending on the scope of the testing to be accomplished. Test cards should contain sufficient information to adequately describe test point and test maneuver execution. For tests requiring coordination between the primary aircrew and the specific test/mission crew, test cards will be provided for the primary aircrew and will be briefed by the test director at the aircrew briefing. Information applicable to the entire test mission may be included on cover cards rather than individual test cards, where appropriate. Test cards should be prepared early enough for sufficient review by the test aircrew. If

ASC/WII DET 3 99-103 10 Feb 2012 9 required, the test cards will be available for the test plan and/or test sortie approval process. Test cards should contain the following information (as applicable):

Test plan test point number Aircraft configuration Aircraft operating limit critical to the test point Test Point initial conditions Challenge and response items, if required Flight test technique required for test point Allowable data bands/parameter tolerances Expected or predicted results Individual test team member responsibilities for test point execution/data collection Risk level, if other than Low Go/No-Go criteria

3.12.3. Test conduct. In general, the scheduling, training, flight documentation, aircrew briefing and mission reporting of all flight tests are accomplished IAW AF and AFMC instructions and are managed by the flight test unit’s flight operations. All test missions will, as a minimum, have a designated PIC and a TD. The test aircrew including the TD will work together to efficiently conduct the approved test points, as described in paragraph 3.5.3 in ISR&SOF I99-103. The TD will decide when to return to base (RTB) for mission accomplishment or in the case of any test anomaly. If any doubt exists about the need to continue testing or RTB, the CT will be consulted for the final decision. The pilot will always have RTB authority.

3.12.3.1. Pilot In Command. The PIC is ultimately responsible for the safe operation of the test aircraft and the efficient completion of the test mission. In addition, the PIC reviews test points and test mission profiles for operational safety and practicality and may make a decision to terminate the mission or test point for any reason, especially if safety of flight is jeopardized. The PIC also directs preflight briefing and mission debriefings and will share mission briefing duties with the test director.

3.12.3.2. Test Director. All tests will have a designated TD who is a member of the aircrew and will decide the order and execution of the individual test points in coordination with the PIC. Normally, the TD will have no other duties, although for simple tests, a mission crew member may also serve as the TD. The TD is responsible for all engineering and support aspects of the mission. The TD will yield to the PIC for final safety-related or operational decisions. The test sequence should be logical and follow a build-up approach using incremental steps. The TD monitors critical data from a technical and safety standpoint and will terminate a test point if a critical parameter limit is being approached or has been exceeded. Criteria for advancement to subsequent test points should be well defined when required. The TD will determine the data quality and, if appropriate, recommend re-accomplishing the test point.

3.12.3.3. Test Card Changes During Test Execution. During test execution, testing will be limited to the procedures defined in the approved set of test cards. Test cards may be deleted or reordered by the TD unless specific inclusion or order is dictated by the TRB or SRB. The TD may approve minor changes to test cards, but the sortie approval authority must approve any significant changes. Test events not defined in the approved set of flight cards are prohibited.

3.12.3.4. Unexpected Test Events: If any test event that the TD (or other member of the test team) consider unexpected occurs, the CT will be called in to assist and advise. The GA-ASI Director of Flight Operations Facilities (DFOF), OL-Det 3 CC, and Det 3 CC will also be notified by the TD.

These notifications will occur only after the safety of the test aircraft is established. Det 3 CC or OL- Det 3 CC will notify the flight operations authority (FOA), as required.

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3.12.3.5. Change in Test Resource Availability: If changes to test resources are required, the TD will coordinate with the CT. The CT will approve and ensure coordination for all changes. The TD’s focus shall remain on the current test points and the health and safety of the mission.

3.13. Test Completion or Termination

3.13.1. Test Reporting.

3.13.1.1. Day of Test Reporting. The TD will be responsible for ensuring a test debrief occurs at the end of every mission. The TD will also ensure that a quicklook report is generated on any day a test mission is performed. Acceptable quicklook formats will be approved by the CT and GA-ASI DFOF. Quicklooks will be sent to the immediate test team (TD, pilot(s), crew and support personnel), as well as the CT, GA-ASI DFOF, Det 3 commander, Det 3 Chief of Engineering, PM and PE. It is the responsibility of the PE to further disseminate test data to other interested parties. Applicable aircrew comments will be incorporated in the Quicklooks.

3.13.1.2. Interim Test Reporting. Interim test reports are not usually contracted or planned, but documentation prepared for the TRRs may be collected and used as an interim test status for outside review.

3.13.1.3. Final Report, The final report will be completed IAW the contract and will be reviewed by the CT to ensure completeness IAW the contract. The PE will ensure and track that the final report is accomplished. Final reports will be reviewed and concurred/non concurred by the Air Force Flight Test Engineer, CT, and Det 3 CC.

3.13.1.4 Government Report. When necessary the government will furnish a test report and staff it appropriately.

3.13.2. Lessons Learned Program. PEs will review appropriate historical lessons learned before commencing a new test project. PEs will document lessons learned regarding test planning, test execution, test reporting and most importantly, test safety throughout the test program. Directions for completing lessons learned worksheets may be found at Attachment 4. These worksheets will be submitted to the Det CT who will ensure that copies are both sent to ASC/WII Test Manager and also archived in the project test file. The ASC/WII Test Manager will review the worksheets and ensure lessons learned are cross-flowed between the Dets and throughout the group. The ASC/WII Test Manager will submit lessons learned worksheets to appropriate outside agencies as required or directed.

3.14. Test File. Test Package Binders can be hardcopy or electronic. Electronic copies are preferred if a common electronic storage location is available that all test team members (ASC/WII’s Det 3 and GA-ASI) can easily access. If a common location cannot be established, an identical set (soft and/or hard copy) will be maintained by both ASC/WII’s Det 3 and GA-ASI. Both binders will be reviewed at the TRR to ensure the entire test team has access to the same information. Binders will include the approved test plan, TRB slides if applicable, approved safety plan, SRB slides if applicable and any other applicable documents. After the TRR, the TRR signoff sheet will be added. The TD is responsible for keeping the binder updated with test cards and quicklook reports. The final test report and lessons learned will be added to close out the file to make it ready for archiving.

4. Test Aircraft Configuration Control. Procedures and documentation for aircraft modifications are covered in AFI 63-131, AFMCI 21-126 and applicable supplements and AFI 63-1101. The T-2 modification process, to include AF Form 1067s, is integral to the test process; however, they are treated as two separate and distinct procedures and Det 3 OI dated 05 April 2010 is mandatory. The TRR is the key place where these processes overlap.

4.1. Partial Flight Manual. The Partial Flight Manuals (PFM) will be developed for aircraft under modification for extended tests. The PFMs will compliment the basic flight manual during the developmental process. Normally, PFMs will be used to modify aircrew procedures resulting from test requirements.

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ASC/WII DET 3 99-103 10 Feb 2012 11

4.2. Modification Flight Manual. Information presented in a PFM format, including tailored aircrew checklists, if required. A Modification Flight Manual (MFM) will be prepared when the modification significantly affects aircraft operations, flying qualities, safety of flight or crew procedures. Any MFMs should be used for test aircraft that are modified with significant and long-term, yet still temporary, test instrumentation.

4.3. Documentation Required in the Ground Control Station. For modifications flown by Det test crews, the AFTO Form 781 aircraft forms binder will be completed IAW AFMCI 21-126. Aircrews will ensure that any applicable PFMs or MFMs are carried on-board the aircraft or are immediately available in the ground control station.

5. Training Requirements.

5.1. Chief of Test Training. The CT appointment or designation approval will include, as a minimum, a demonstrated understanding of the following: AFMC basic acquisition, applicable test instructions, approved test-related ASC/WII’s Det 3 and contractor procedures, AFI 91-204 and incident reporting, all test related MOAs and COAs, test range coordination, applicable chains of command and organizational structure, Crew Resource Management (CRM), all on-going AFMC MQ-1 and MQ-9 test projects, MQ-1 and MQ-9 operation and emergency procedures and the DFO’s roles and responsibilities. Final approval in an appointment letter signed by the ASC/WII/CC is also required.

5.2. Test Director Training. The TD appointment or designation approval will include, as a minimum, a demonstrated understanding of the following: applicable test instructions, approved test-related ASC/WII’s Det 3 and contractor procedures, basic AFI 91-204 and incident reporting, all test-related MOAs and COAs, test range coordination, applicable chains of command and organizational structure, CRM, MQ-1 and MQ-9 operation and emergency procedures, detailed components of a test package, test package approval cycle and information contained in the respective aircraft technical order. For conducting performance and flying qualities test points, an additional endorsement of a more thorough understanding of the aircraft’s stability augmentation system and autopilot system is required. Det CT with nominate TD candidates for Det 3/CC approval.

ANDREW B FREEBORN, LtCol, USAF, PhD Commander ASC/WII Det 3

Attachments:

1. Test Project Safety Review Form or Equivalent, Sample Test Project Safety Review

2. Test Readiness Review Checklist

3. Lessons Learned Program

SECTION IV: PROJECT DESCRIPTION

1. BACKGROUND

2. TEST OBJECTIVES

3. TEST ITEM DESCRIPTION

4. SYSTEM MATURITY

5. PREDICTED/EXPECTED RESULTS

6. TYPES OF TESTS

7. SCOPE

8. DIFFERENCES FROM PREVIOUS TESTS

9. REFERENCES

SECTION V: SAFETY REVIEW SUMMARY

1. REVIEW SYNOPSIS

TRB Minutes/Membership/Risk Assessment

SRB Minutes/Membership/Risk Assessment

2. MISHAP RESPONSIBILITIES

3. GENERAL MINIMIZING PROCEDURES / TEST HAZARD ANALYSES

4. QUALIFICATION AND TRAINING

5. TEST ARTICLE RESTRICTIONS

6. SPECIAL CONSIDERATIONS

7. ACTION ITEMS

8. RISK ASSESSMENT: LOW/MEDIUM/HIGH

9. COORDINATION COMMENTS:

Test Readiness Review

PROJECT TITLE: Date:

All items should be completed prior to the Test Readiness Review. After review, forward checklist to Chief of Test for filing in the Test File.

RISK LEVEL Approval Authority Approval Date LOW OL-Det 3/CC or CT or Det 3/CC

MEDIUM ASC/WII via formal TRR HIGH ASC/WI via formal TRR

Test Documentation

Completion

Date Remarks

Test Plan Test Plan Approved/Signed Test Plan Amendments Approved/Signed Technical Review Board Minutes in TPSR/Action Items completed Safety Review Board Minutes in TPSR/Action Items completed GA Aircraft Flight Approval (AFA) approved/signed TPSR Approved/Signed TPSR Amendments Approved/signed Test Cards Reviewed by Test Team and approved by Approval Authority

Configuration Documentation

Remarks

T-2 Modification Packages (identify in Remarks) Aircraft

GCS

External Technical Orders Baselines Flight Manual/Checklists identified/available Draft/Red-lined Flight Manual/Checklists available Airworthiness Airworthiness Approved by ASC/EN and in CT files

Mission Readiness

Remarks

Range Safety Coordination completed (weapon footprints, laser firings, FRR, etc.)

Frequency Clearances secured/scheduled (telemetry, radios, pod emissions, etc)

Instrumentation Installed/Checked (TM Van, HF TM, etc) Security Considerations addressed (COMSEC, OPSEC, Key Loaders, GPS Keys, etc)

Ground Test Results/WITS/Known Anomalies/Aircrew Impact/Go-No Go Items briefed at TRR

Aircrew Training/Simulations completed Airspace/Range scheduled (targets, Pred Box, comms, etc) Aircraft/GCS configuration sheet competed

ACTION ITEMS TO PROCEED:

Lessons Learned Program

LESSONS LEARNED

The purpose of the Lessons Learned Program is to give acquisition managers, maintainers, logisticians, designers, users and supporters feedback on the results of past design and acquisition decisions for application to current and future acquisition programs. Its goal is to improve the conduct of research, development and T&E and to improve system life-cycle cost and performance. It is an important part of the technical reporting process. Lessons Learned come primarily from test reports but can result from development projects, daily support activities or personal observations by individuals. They can be submitted at any time, not just at the end of a test program.

TOPIC

LESSON LEARNED

PROBLEM

DISCUSSION

APPROPRIATE ACTION

PREPARING ACTIVITY

LESSON CATEGORY

PROGRAM PHASE

Briefly describe the content of the lesson.

State in one or two brief sentences the single most important finding. This statement should not recommend action; it should set forth a causal relation. For example, “Application of power to sensitive components during extended maintenance actions may cause undetected damage and subsequent catastrophic in-flight failure.”

If the lesson is negative, describe what went wrong in a brief, general statement, preferably no longer than one or two sentences. If the lesson concerns a successful practice or innovation, leave this section blank.

Give enough background for this item so the reader can understand the conditions that led to the problem or resulted in an improvement and can properly distinguish between cause and effect. The information is succinct but in sufficient detail to allow a user of the lesson to tailor it for a particular application.

This is the most important part of the Lessons Learned document. It must provide the reader with a course of action, time phase and vehicle to carry out the lesson.

Contact point/organization symbol/DSN number.

Indicate one or more categories selected from the following list: 1) Configuration Management; 2) Data Management; 3) Contractor Interface; 4) Integrated Logistics Support; 5) Intelligence; 6) Manufacturing/Production Management; 7) Packaging and Transportation; 8) Procurement/Contracting; 9) Program Control; 10) Program Management; 11) Requirements Establishment;

12) Support Equipment; 13) System Engineering; 14) Test and Evaluation; 15) Training; 16) Using Command/Support Command Interface; 17) Computer Resources; 18) Facilities; 19) Maintenance Concept; 20) Reliability and Maintainability; 21) Safety; 22) Human Factors; 23) Lifecycle Costs; 24) Deficiency Reports; 25) Instrumentation; 26) Class II Modification; 27) Technical Orders; 28) Source Selection; 29) Other; 30) Environmental Planning and 31) Manpower.

List the appropriate program phase to which the lesson applies. Use the following phases: 1) Planning; 2) Provisioning; 3) Execution; 4) Analysis and Reporting or 5) Not Applicable

Note: The entire lesson usually does not exceed one page. Submit additional data and findings as backup information to the lesson learned summary sheet.

Lessons Learned

Project: __________________ Test Title: __________________ Date: __________________

TOPIC:

LESSON LEARNED:

PROBLEM:

DISCUSSION:

APPROPRIATE ACTION:

PREPARING ACTIVITY:

LESSON CATEGORY:

PROGRAM PHASE: