4_ECH_LAT_Component_Plan_DRAFT_070816.pdf

Lot Acceptance Test (LAT) Plan

For

Enhanced Combat Helmet

Component Level Testing

VERSION 4

Draft as of 08 Jul 16

Approved by:

R. O. Bailey

LtCol, USMC

Product Manager, Infantry Combat Equipment

Date Signed

Record of Change

Version Date Paragraph Comment Approval 1 6-28-13 Original 2 3-21-14 7 Updated Lot quantity sizes and test quantities

3 7-18-14 4.2, 4.3, 4.4;

7 (Table V Footnote);

7.1; 7.1.1.3;

Appendix A

Added paragraphs on sampling procedures and helmet availability; misc grammatical errors; deleted “Exceptions

Memorandum”; made changes to reflect current revision of IOP-

003 (no Exceptions Memorandum); Added Appendix A References

4 TBD TBD TBD

LOT ACCEPTANCE TEST (LAT) PLAN

FOR

ENHANCED COMBAT HELMET (ECH)

COMPONENT LEVEL TESTING

1 Scope

This document contains the Lot Acceptance Test (LAT) plan for the Enhanced Combat Helmet (ECH).

Components will be tested prior to assembly into helmets or including in repair kits (if ordered). Testing of items of the components prior to assembly into helmets will preclude components from a sub-standard component lot from entering production and potentially being delivered, especially if the component lot is large and spans many helmet lots.

This document contains the following component tests:

Retention System:

- Retention System (type and quality or retention system)

- Marking of Retention Systems

- Hardware 9mm Resistance to Penetration

- Static Pull

Pad Suspension System

- Marking of Pad Suspension Systems

- Blunt Impact

- Pad Water Absorbency

NVD Hardware 9mm Resistance to Penetration

2 Classification

The ECH is of one Type (tactical cut) and one Class. The helmet shell and retention system color requirements are detailed in the applicable contract and purchase description.

3 Schedule of sizes

This LAT plan is applicable for the following ECH sizes:

SCHEDULE OF SIZES

Small (S)

Medium (M) Large (L)

Extra-Large (XL)

4 Lot Acceptance Testing Concept

The Lot Acceptance Testing (LAT) will ensure the contractor provides a consistent product in accordance with the GL-PD-09-04 that was qualified during First Article Testing. Sampling and acceptance/rejection criteria shall be in accordance with this test plan. The lot will be accepted when it meets both the minimum requirements for each individual requirement and meets the minimum acceptance level across the overall set of samples selected for testing. This concept will ensure the ECH Program is responsive to the Office of the

Secretary of Defense (OSD), Director of Operational Test and Evaluation’s (DOT&E) Military Combat Helmet

Standard for Ballistic Lot Acceptance Testing (accept/reject rates based on number of test event failures) while maintaining industry standards for Lot Acceptance in accordance with ANSI/ASQ Z1.4 (accept/reject rates based on number of defective helmets).

4.1 Sampling Selection

Samples shall be randomly selected from each of the individual items within the respective lot (Suspension

System, Retention Systems with hardware) by DCMA representative at the source/manufacture location. The

Defense Contract Management Agency (DCMA) Quality Assurance Representative (QAR) may elect to select more samples than is indicated in Table IV and VI in order to expedite the shipment of sample to the test lab if defective samples are found during the non-destructive inspecting/testing. Defective samples shall not be sent to destructive testing.

4.2 Mandatory Source Sampling

The procedures of for component lot approval of NIB-manufactured components (suspension pad sets and retention systems) will proceed in order as follows:

(a) NIB manufacturing facility will notify Contractor when a lot is ready to be tested. NIB will notify

QAS.

(b) Quality Assurance Representative Specialist (QAS) at NIB manufacturing facility will select the requisite number of samples (delineated in Table IV).

(c) Selected component samples will be shipped to Contractor.

(d) QAS at Ceradyne will select the requisite number of helmet samples (selected from component helmet test lot on hand)(note that specific sizes are required depending on the test, delineated in

Table VI).

(e) Contracot will assemble the components under test (received from NIB plant) into the helmet

(selected from test lot on hand).

(f) Components will undergo the appropriate lot testing (Table VI).

(g) Lot Testing reports will be provided to the ECH Program Office and uploaded into SMARRTED grading system.

(h) Lot Acceptances will be approved in SMARRTED and the Contactor DCMA representative will be notified via SMARRTED.

4.3 Non-Mandatory Source Sampling

The procedures for component lot approval of non-NIB-manufactured components, if any, will proceed in order as follows:

(a) Contractor will receive a lot of components from their supplier.

(b) Contractor will notify the QAS at the Ceradyne facility that a non-NIB component lot is ready for sampling

(c) QAS at Contractor will select the requisite number of components and helmet samples (selected from component helmet test lot on hand)(note that specific sizes are required depending on the test, delineated in Table VI).

(e) Contractor will assemble the components under test into the helmet

(f) Components will undergo the appropriate lot testing.

(g) Lot Testing reports will be provided to the ECH Program Office and uploaded into SMARRTED grading system.

(h) Lot Acceptances will be approved in SMARRTED and the Contractor DCMA representative will be notified via SMARRTED.

4.4 Helmet Availability for Component Tests

Most of the component tests are system-level tests, ( i.e. the test requires the component to be installed in a helmet and the helmet tested as a system). This requires helmets to be readily available. The Contractor will manufacture lots helmets of each size and set it aside for component testing purposes. These shall be known as the component helmet test lots. Several of the component tests require helmet shells to be used in conjunction with the tested component (system level test). Helmet shells used for these component tests may be cosmetically blemished helmets. Cosmetically blemished shall consist of any of the defects listed in ECH PD paragraph 3.5.1 or the following defects listed in Paragraph 4.3, Table I: any permissible gap or pit not resin filled as specified, shell outer and inner surfaces are not smooth and even (in process inspection), shell exposed ends of fabric fiber showing, shell raised fibers, pleats, wrinkles or creases longer than 1 inch, any benchmark omitted, not visible, or obliterated, edging with any cut, tear or hole, any edging not adhered to shell, any coating defect, any marking of shell defect, or any barcode label defect.

4.1.1 Individual Requirement Acceptance Criteria

The minimum acceptance criteria for the individual requirements are based on the number of failed components for that requirement. Individual requirement acceptance/rejection criteria selected were based on the OSD

DOT&E Military Combat Helmet Standard for Ballistic Lot Acceptance Testing, American National Standard

(ANSI) Z1.4-2008, and current helmet program acceptance criteria. The samples shall meet Certificate of

Compliance, Non-Destructive requirements, and Destructive Requirements in order for the lot to be accepted.

4.2 Test Events

4.2.1 Destructive Testing

A specific number of helmets will be allocated toward each individual component test required. The individual component test requirements (9mm Hardware Resistance to Penetration, etc) are described in the below.

4.2.2 Non-destructive Testing

A specific number of helmets will be allocated toward each individual non-destructive component test required.

Non-destructive testing shall take place prior to destructive testing.

4.3 Testing Facilities

Testing will be conducted at the facilities outlined in Table I and witnessed by the Government.

Table I. Testing Facilities

Requirements US Marine Corps, Class I

Destructive

Ballistic Testing (9mm

Hardware RTP) Certified Ballistic Laboratory1

Blunt Impact, Retention

System Static Pull, Pad Layer

Material (water absorbency)

Contractor selected facility1

Non-

Destructive

Retention System, Marking of Retention Systems, Marking of Pad Suspension

Systems

Contractor with DCMA witness or Contractor selected facility1

1 Facilities chosen by the contractor must be capable of accurately obtaining and documenting the required data of this test plan. All test facilities shall be inspected and approved by the Government prior to conducting testing. Aberdeen Test Center (ATC) will be responsible for the inspection and approval of all ballistic test facilities. A successful pre-test exercise will be required at all facilities prior to the initiation of testing. If any shortcomings are identified in the pre-test exercise, they shall be remedied prior to lot testing.

The government will have Independent Observers present during the ECH Lot Acceptance Testing. These independent observers will be either from the US Army Aberdeen Test Center or from the Marine Corps

Operational Test and Evaluation Activity (MCOTEA). Additionally, observers from the Director, Operational

Test and Evaluation (DOT&E) and PdM ICE may be present. The independent observers from ATC and

MCOTEA will be specifically trained in ECH LAT procedures and protocols. The Independent Observation

Team will consist of a Test Officer and a Data Collector. The Test Officer will be observing all elements of the

ECH LAT process and the Data Collector will be independently collecting test data. The Independent

Observation test officer will be observing compliance with the ECH LAT Detailed Test Plan and the associated test procedures and protocols associated with ECH testing. The Independent Observation Team will be producing an Independent LAT report for each LAT specifically for the government. The contractor selected test facility will make reasonable efforts to accommodate the Independent Observation Team, and other authorized government observers, and provide them access to LAT data as it is collected. If a discrepancy with regard to Test Procedures is brought forward by the Independent Observation Team, the contractor selected test facility personnel will make all reasonable attempts to rapidly resolve the discrepancy. If the discrepancy, cannot be readily be resolved, the contractor selected test facility will contact the Contractor immediately and provide the details of the discrepancy. The Contractor will provide amplifying guidance to the contractor selected test facility with regard to resolving the discrepancy. The contractor selected test facility will conduct a preliminary data reconciliation meeting with the Independent Observation Team at the end of each test day and a final data reconciliation meeting at the end of each specific individual LAT. The contractor selected test facility should work with the Independent Observation Team to resolve any data discrepancies. If there are any unresolved data discrepancies, these discrepancies should be immediately forwarded to the Contractor. All government observers will abide by all contractor selected test facility safety procedures and policies.

4.8 Standard Ambient Conditions

Examinations, inspections, and testing shall be conducted in standard ambient conditions of 68°F (+10°F)/20°C

(+5.6°C) and a relative humidity (RH) of 50% (+20%) and site atmospheric pressure, unless otherwise specified herein.

4.9 Retesting

Examinations, inspections, and testing shall be conducted only once. If the test was conducted incorrect (not in accordance with requirements), retesting shall be allowed. The test report shall report both original test and the retest results along with a detailed explanation as to what was incorrect in the original test. With the exception of the Padding Layer Test (pad water absorption), in cases where the test was conducted in correctly but the item failed the test, retesting is only allowed with the express permission of the Program Office. One retest shall be allowed, without Program Office approval, for water absorption tests. The test report shall report both the original and retest results along with a statement indicating the restest was authorized.

5 Requirements and Verification of Certification of Compliance Items

The Contractor shall deliver the Certification of Compliance (CoC) in accordance with the contract. The CoC will address each of the requirements and certify that the materials and manufacturing processes have not changed since the last physical configuration audit (PCA) and/or FAT. The lot shall be accepted in accordance with this paragraph (see Table II) when the Government receives the CoC.

Table II. Requirements and Verifications for Certification of Compliance Items

Characteristic Requirement Paragraph of PD Verification

Paragraph of PD Lot Acceptance

Attachment holes 3.5.4 4.3 2/ Retention system holes 3.5.4.1 4.4 2/

Night vision goggle holes 3.5.4.2 4.8 2/ Retention system 3.6 4.3 2/ Attaching hardware 3.6.2 4.3, 4.11.2, 4.18.2 2/ Retention system dynamic pull strength

3.6.4 4.11.3.1, 4.11.3.3 2/

Pad suspension system 3.7 4.12.1 2/ Pad construction 3.7.1 4.3 2/ Inner layer material 3.7.1.1 4.12.4, 4.15 2/ Outer layer material 3.7.1.3 4.3, 4.15 2/ Pad compression durability

3.7.2 4.12.2 2/

Hook disks 3.8 4.13.1, 4.15 2/ Hook disk shape and coverage

3.8.1 4.13.1 2/

Hook disk durability 3.8.2 4.13.2, 4.13.3 2/ Hook/loop adhesion 3.8.3 4.13.4 2/ Seawater resistance 3.12.1 4.19, 4.21.1 2/ Weatherometer resistance 3.12.2 4.21.2 2/ Field agent resistance 3.12.3 4.21.3 2/ Flame resistance 3.12.4 4.21.4 2/ High Temp storage/use 3.12.5 4.21.5 2/ Cold Temp storage/use 3.12.6 4.21.6 2/ Temperature shock 3.12.7 4.21.7 2/ Altitude 3.12.8 4.21.8 2/ Vibration 3.12.9 4.21.9 2/ Impact resistance 3.12.10 4.21.10 2/ Salt Fog 3.12.13 4.21.13 2/ Washability 3.13.5.1 4.22.1 2/ Colorfastness 3.13.5.2 4.14 2/ Accelerated Aging /Shelf Life

3.13.6 4.21.14 2/

Safety 3.14.1 4.22.2 2/ Toxicity 3.14.2 4.22.2 2/

Hazardous Materials 3.14.3 4.22.2 2/

1/ Not applicable

2/ Certificate of compliance shall be provided certifying that the design and materials of the helmet have not changed since approval of FAT and in accordance with PD Paragraph 4.1.4. The Government reserves the right to inspect or test such items to verify the validity of the certification.

6 Requirements and Verifications for Non-Destructive Items

Helmets for Non-Destructive testing will be chosen at random from lot. The random selection shall be done prior to initiating a LAT using the serial numbers provided by the contractor. Items requiring certificate of conformance will be submitted in accordance with the contract statement of work. Table III lists the requirements for non-destructive characteristics and Table IV lists the quantity tested and accept/reject criteria.

Table III. Requirements and Verifications for Non-Destructive Test Characteristics

Requirement Paragraph of PD Verification

Paragraph of PD Lot Acceptance

1/

Retention System 3.6 AR/PD 12-01 x2/3/ Marking of pad suspension 3.13.2 4.3, 4.22.1 x3/

1/ An “x” in the column designates that the test is performed. Sampling rates IAW Table D01.

2/ Non-destructive testing for Retention Systems shall include Visual and Dimensional Examinations (Annex

A, Table II of AR/PD 12-01. Sampling rates IAW Table ND01.

3/ Test in accordance with applicable paragraph in GL-PD 09-04L.

Table IV. Non-Destructive Single Sampling for Normal Inspection

Characteristic Lot Size ANSI Z1.4 Basis Quantity

Tested

Accept (# failures)

Reject (# failures)

Retention System

(AR/PD 12-01)

91-150 S-3, AQL 4.0, C 3 0 1

151-280 S-3, AQL 4.0, D 13 1 2

281-500 S-3, AQL 4.0, D 13 1 2

501-1200 S-3, AQL 4.0, E 13 1 2

1201-3200 S-3, AQL 4.0, E 13 1 2

3201-10000 S-3, AQL 4.0, F 20 2 3

Hook Disk Durability

91-150 S-3, AQL 4.0, C 3 0 1

151-280 S-3, AQL 4.0, D 13 1 2

281-500 S-3, AQL 4.0, D 13 1 2

501-1200 S-3, AQL 4.0, E 13 1 2

1201-3200 S-3, AQL 4.0, E 13 1 2

3201-10000 S-3, AQL 4.0, F 20 2 3

Marking of pad suspension

91-150 S-3, AQL 4.0, C 3 0 1

151-280 S-3, AQL 4.0, D 13 1 2

281-500 S-3, AQL 4.0, D 13 1 2

501-1200 S-3, AQL 4.0, E 13 1 2

1201-3200 S-3, AQL 4.0, E 13 1 2

3201-10000 S-3, AQL 4.0, F 20 2 3

7 Requirements and Verification for Destructive Requirements

Once having passed non-destructive testing, the selected helmets shall be subjected to ballistic and non-ballistic destructive testing. The lot shall be accepted in accordance with this paragraph when the lot meets the acceptance criteria in Table VI for the individual requirements.

Table V. Requirements and Verifications for Destructive Inspection Characteristics

Requirement Paragraph of PD Verification

Paragraph of PD Lot Acceptance

1/

Retention System (AR/PD 12-01)

3.6.3 AR/PD 12-01 x2/4/

Padding layer material (water absorbency)

3.8.1.1 4.3, 4.12.3 x 3/

Retention System Hardware Resistance to penetration – 9mm

3.6.3 AR/PD 12-01 2/ x 3/

NVD Hardware Resistance to penetration – 9mm

3.7 4.18.2.1 x 3/

Blunt impact protection 3.11 4.20 x 3/

1/ An “x” in the column designates that the test is performed. Sampling rates IAW Table D01.

2/ Destructive testing for Retention Systems shall include Static Pull Strength (3.5.2.1, 4.4.5 of AR/PD

12-01) and Resistance to Penetration (3.5.3.b, 2 rear shots, 4.4.b). Sampling rate IAW Table D01.

3/ Test in accordance with applicable paragraph in GL-PD 09-04L.

Table VI. ECH LAT Single Sampling for Normal Inspection – Destructive

Characteristic Lot Size ANSI Z1.4 Basis Number of

Shots/Impacts

Quantity Tested

(Number of

Helmets)

Accept (# failures)

Reject (# failures)

Retention System Hardware RTP 9mm

91-150 DOTE 6 3 0 1

151-280 DOTE 10 5 0 1

281-500 DOTE 10 5 0 1

501-1200 DOTE 10 5 0 1

1201-3200 DOTE 16 8 1 2

3201-10000 DOTE n/a

NVD

Hardware

RTP

91-150 S-4, AQL 4.0, D 26 13 1 2

151-280 S-4, AQL 4.0, E 26 13 1 2

281-500 S-4, AQL 4.0, E 26 13 1 2

501-1200 S-4, AQL 4.0, F 40 20 2 3

1201-3200 S-4, AQL 4.0, G 64 32 3 4

3201-10000 S-4, AQL 4.0, G 64 32 3 4

Blunt Impact 91-150 S-4, AQL 4.0, D 182 1/ 13 1 2

151-280 S-4, AQL 4.0, E 182 13 1 2

281-500 S-4, AQL 4.0, E 182 13 1 2

501-1200 S-4, AQL 4.0, F 280 20 2 3

1201-3200 S-4, AQL 4.0, G 448 32 3 4

3201-10000 S-4, AQL 4.0, G 448 32 3 4

Characteristic Lot Size ANSI Z1.4 Basis Number of

Shots/Impacts

Quantity Tested

(Number of

Helmets)

Accept (# failures)

Reject (# failures)

Retention System Static Pull

91-150 S-4, AQL 4.0, D 13 13 1 2

151-280 S-4, AQL 4.0, E 13 13 1 2

281-500 S-4, AQL 4.0, E 13 13 1 2

501-1200 S-4, AQL 4.0, F 20 20 2 3

1201-3200 S-4, AQL 4.0, G 32 32 3 4

3201-10000 S-4, AQL 4.0, G 32 32 3 4

Pad Water Absorbency

91-150 S-3, AQL 4.0, C 3 2/ 3 0 1

151-280 S-3, AQL 4.0, D 13 13 1 2

281-500 S-3, AQL 4.0, D 13 13 1 2

501-1200 S-3, AQL 4.0, E 13 13 1 2

1201-3200 S-3, AQL 4.0, E 13 13 1 2

3201-10000 S-3, AQL 4.0, F 20 20 2 3

1/ Number of impacts represents two hits on seven locations on each helmet.

2/ In exception to paragraph 4.12.3 of the PD, the water absorbency test shall be conducted on complete sets of pads (one crown, two trapezoid, four oblongs).

Appendix A

References

1. Purchase Description for the Enhanced Combat Helmet, GL-PD-09-04L, U.S. Marine Corps System

Command, Program Manager Infantry Combat Equipment, Attn: PM Infantry Combat Equipment, 2200 Lester

Street, Quantico, VA 22134-6050, 13 December 2013.

2. Purchase Description for the Improved Retention System, AR/PD 12-01, U.S. Army, Program Manager

Soldier Protective Equipment, 10170 Beach Road, Building 328T, Fort Belvoir, VA, 02 December 2015.