5_ECH_LAT_Plan_v7_DRAFT_070716.pdf

Lot Acceptance Test (LAT) Plan

For

Enhanced Combat Helmet

VERSION 7.0

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

0.1 13 April 09 Draft Published for RFP

0.2 14 Jul 09

Para 4, Table Notes Updated Draft for contract award

0.3 16 Feb 11

Various Update from PD changes after DT and DOT&E guidance

1.0 2 May11 Approved LAT Plan

2.0 15 May 12 Updated LAT Plan

3.0 18 Oct 13 Various Updated for single sizing and other minor clarifications

4.0 1 Nov 13 Various Updated shot orders to be more clear, updated bolt criteria

5.0 13 Dec 13 Various Revised retention system fair hit criteria and retention static pull test procedure

6.0 18 Jun 14 6, 7.0, 7.1.4.3.p, 7.2.2.2

Revised quantities tested per lot and accept/reject criteria, Added

, Night Vision Goggle Holes, and, Hook Disk as LAT tests;

Added option for pad water absorption testing as component prior to installing in helmet;

deleted BFD as a small arms data requirement; changed

“various” to “ambient”

7.0 TBD TBD TBD

LOT ACCEPTANCE TEST (LAT) PLAN

ENHANCED COMBAT HELMET (ECH)

1 Scope

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

ECH is a protective helmet consisting of a ballistically protective shell, pad suspension system, and retention system. The ECH is compatible with, and is typically worn in conjunction with other components of infantry combat equipment such as body armor systems, protective spectacles/goggles and/or prescription glasses, night vision equipment, and a camouflage fabric helmet covers. Unless otherwise stated herein, all requirements and verification methods shall be those prescribed in the contract and associated attachments, including Purchase

Description (GL-PD 09-04).

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). This lot acceptance plan is used in conjunction with the Lot

Acceptance Plan for ECH Component Level Testing. Certain components must be lot tested before being installed in helmets. This plan assumes the use of components that have been approved via a component LAT test.

4.1 Sampling Selection

Lots shall be helmets of a single size. Samples shall be randomly selected from all helmets within the lot. The random selection shall be done by the Government prior to initiating a LAT using the serial numbers provided by the contractor. Paragraph 11, Table IX indicates the number of samples to be selected for LAT. The

Defense Contract Management Agency (DCMA) Quality Assurance Specialist (QAS) may elect to select more samples than is indicated in Table IX 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 Acceptance Criteria In order for a lot to be considered acceptable, it shall meet individual requirements

(tests for specific individual requirements such as 9mm resistance to penetration and paint adhesion) as well as the helmet overall requirement (sample requirement).

4.2.1 Individual Requirement Acceptance Criteria

The minimum acceptance criteria for the individual requirements are based on the number of failed helmets for that requirement. Multiple failures on one helmet are possible and will be counted as a single defective helmet.

Individual requirement acceptance/rejection criteria selected were based on the OSD DOT&E Military Combat

Helmet Standard for Ballistic Lot Acceptance Testing and current helmet program acceptance criteria.

4.2.2 Helmet Sample Acceptance Criteria

The minimum acceptance criteria of the entire sample selected for the test will be based on the number of helmets sustaining one or more failures. Multiple failures on one helmet are possible and will only be counted as a single defective helmet. ANSI/ASQ Z1.4 was used as guidance for selecting sampling and acceptance/rejection criteria for the overall acceptance.

4.3 Test Events

4.3.1 Destructive Testing

The entire helmet sample cannot be tested for all requirements. Therefore, a specific number of helmets will be allocated from the overall required helmet sample and tested for specific individual requirements. The destructive testing shall not be conducted until the non-destructive testing is complete.

4.3.2 Non-destructive Testing

The entire selected sample will be tested for all non-ballistic requirements prior to destructive testing.

4.4 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

Destructive

Ballistic Testing (17-grain, 9mm Shell

RTP/BTD, 9mm NVG Hardware, and Small

Arms RTP)

Certified Ballistic Laboratory1

Blunt Impact, Retention System Static Pull, Pad

Layer Material, and Adhesion of Coating Contractor selected facility1

Non-

Destructive Edging Adhesion, Marking of Shell and Weight Contractor with DCMA witness

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/PM SPE 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 Ceradyne immediately and provide the details of the discrepancy. Ceradyne 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 Ceradyne. All government observers will abide by all contractor selected test facility safety procedures and policies.

4.6 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.

4.7 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) for Class I helmets, 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 Type I helmet water absorption tests.

The test report shall report both the original and retest results along with a statement indicating the retest 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

Interchangeability 3.4.1 4.1.4 2/ Shell design/shape 3.5 4.4 2/

Requirement Paragraph of PD Verification

Shell construction 3.5.1 4.3 2/ Shell thickness and uniformity

3.5.2 4.5 2/

Benchmarks 3.5.3 4.6, 4.3 2/ Edging 3.5.5 4.3, 4.9.1 2/ Edging adhesion after heat aging

3.5.5.2 4.9.3 2/

Coating 3.5.6 4.3 2/

Surface preparation 3.5.6.1 4.1.4 2/

Texturing of coating 3.5.6.2 4.3 2/ Sand texturing 3.5.6.2.1 4.1.4 2/ Walnut shell flour texturing

3.5.6.2.2 4.1.4 2/

Color 3.5.6.3 4.15 2/ Infrared reflectance 3.5.6.4 4.16 2/ Specular gloss 3.5.6.5 4.17 2/ Retention system attachment points

3.6.1 4.11.1, 4.4 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/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/ Compression resistance (top to bottom).

3.12.11 4.21.11 2/

Compression resistance (side to side).

3.12.12 4.21.12 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/

Requirement Paragraph of PD Verification

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 of PD Verification

Paragraph of PD Lot Acceptance

1/

NVG Holes 3.5.6 4.8 x 2/ Edging adhesion 3.5.7.1 4.9.2 x 2/ Retention System Attaching Hardware

3.6.2 4.11.2 x 2/3/

NVD Bracket and Attaching Hardware

3.7 4.11.2 x 2/4/

Hook Disk Durability 3.9.2 4.13.2, 4.13.3 x 2/

Weight 3.11 4.19 x 2/

Marking of helmet shell 3.14.1 4.3, 4.22.3 x 2/

1/ An “x” in the column designates that the test is performed. Sampling rate is specified Table XX.

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

3/ Compatibility with the X-back Retention System and Ceradyne hardware need not be tested.

4/ Hardware thickness on the inside of the shell need not be tested.

Note that lots of components (retention systems and pad suspension systems) will be tested for LAT requirements at the component level prior to assembly into finished helmets. Inspection for Retention System

(except Torque), Marking of Pad Suspension and Marking of Retention Systems may be conducted on samples selected from component lots at the manufacturer’s facility (NIB/other subcontractor) and inspected at rates in accordance with the Component LAT Plan. If conducted at the component level, inspection is not required during LAT testing of the finished helmet. If tested at the component level, evidence of successful inspection at the component level shall be submitted to the PM office by DCMA with inspection reports of the assembled lot.

Additionally, data linking the component lots to the assembled lot shall be submitted. Torque shall be conducted during LAT of the finished helmet.

Table IV. ECH LAT Single Sampling for Normal Inspection – Non-Destructive

Table IV. Non- Destructive Single

Sampling for Normal Inspection Characteristic

Lot Size

ANSI Z1.4 Basis Quantity Tested

Accept failures) Reject

(# failures)

NVG Holes 91-150 S-3, AQL 4.0, C 5 0 1

151-280 S-3, AQL 4.0, D 8 1 2

281-500 S-3, AQL 4.0, D 8 1 2

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

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

Edging adhesion 91-150 S-3, AQL 4.0, C 5 0 1

151-280 S-3, AQL 4.0, D 8 1 2

281-500 S-3, AQL 4.0, D 8 1 2

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

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

Retention System Attaching Hardware

91-150

S-3, AQL 4.0, C

151-280 S-3, AQL 4.0, D 8 1 2

281-500 S-3, AQL 4.0, D 8 1 2

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

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

NVD Bracket and Attaching Hardware

91-150 S-3, AQL 4.0, C 5 0 1

151-280 S-3, AQL 4.0, D 8 1 2

281-500 S-3, AQL 4.0, D 8 1 2

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

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

Hook Disk Durability 91-150 S-4, AQL 4.0, D 8 1 2

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

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

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

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

Weight 91-150 G-I, AQL 4.0, D 8 0 1

151-280 G-I, AQL 4.0, E 13 0 1

281-500 G-I, AQL 4.0, F 20 0 1

501-1200 G-I, AQL 4.0, G 32 0 1

1201-3200 G-I, AQL 4.0, H 51 0 1

Marking of helmet shell 91-150 S-3, AQL 4.0, C 5 0 1

151-280 S-3, AQL 4.0, D 8 1 2

281-500 S-3, AQL 4.0, D 8 1 2

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

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

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 V and Table VI for the individual requirements, and Table VII for the combined destructive test criteria.

Table V. Requirements and Verifications for Destructive Inspection Characteristics of PD Verification

Paragraph of PD Lot Acceptance

1/

Adhesion of coating 3.5.6.6 4.10 x 2/ V50 ballistic protection limits – (V50 BL(P))

3.9.1 4.18.1 x 2/

Resistance to penetration – Shell 9mm

3.9.2.1 4.18, 4.18.2 x 2/

Resistance to penetration – Small Arms

3.9.2.2 Classified Annex A

X2/

Ballistic transient deformation

3.9.3 4.18, 4.18.2 Classified Annex A x 2/

Blunt impact protection 3.11 4.20 x 2/

1/ An “x” in the column designates that the test is performed. Sampling rate is specified Table XX..

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

Note that lots of components (retention systems, pad suspension systems, and hardware ) shall be tested for

LAT requirements at the component level prior to assembly into finished helmets. Testing for Retention system static pull, Padding layer material, and Resistance to Penetration (hardware) will be conducted on samples selected from component lots at the manufacturer’s facility (NIB/other subcontracor) and tested at rates in accordance with the Component LAT Plan. When conducted at the component level, testing is not required during LAT testing of the finished helmet. When tested at the component level, evidence of successful testing at the component level shall be submitted to the PM office by DCMA with inspection reports of the assembled lot. Additionally, data linking the component lots to the assembled lot shall be submitted.

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

Test Lot Size Number of

Shots/Impacts Quantity Tested

(Number of Helmets)

Accept (# failures)

Reject (# failures)

Resistance to penetration/BFD – Shell 9mm

91-150 16 8 1 2

151-280 16 8 1 2 281-500 16 8 1 2 501-1200 26 13 1 2

1201-3200 26 13 1 2

Resistance to penetration – Small Arms

91-150 3 3 0 1

151-280 5 5 0 1 281-500 5 5 0 1 501-1200 5 5 0 1 1201-3200 8 8 1 2

Test Lot Size Number of

Shots/Impacts Quantity Tested

(Number of Helmets)

Accept (# failures)

Reject (# failures)

V50 ballistic protection limit – (V50 BL(P))(17 gr)

91-150 a/r 1 1/ 0 1

151-280 a/r 1 1/ 0 1 281-500 a/r 1 1/ 0 1 501-1200 a/s 1 1/ 0 1 1201-3200 a/r 1 1/ 0 1

Blunt Impact Protection

91-150 21 3 0 1

151-280 21 3 0 1 281-500 21 3 0 1 501-1200 35 5 1 2 1201-3200 35 5 1 2

Adhesion of Coating 91-150 - 1 0 1 151-280 - 1 0 1 281-500 - 1 0 1 501-1200 - 1 0 1 1201-3200 - 1 0 1

1/ Multiple helmet shells may be required to determine the V50 BL(P).

If a LAT fails the Resistance to Penetration 9mm/BFD for the Shell for a particular location(s) as indicated in

Table VI (hereafter call the “base LAT”), additional testing to approve the lot is permitted (hereafter called

“Tier II LAT”). An additional 42 helmet samples shall be tested for a side or front test while an additional 41 helmet samples shall be tested for crown or back. In the case of side shots, the additional 42 shots should be split evenly between left and right sides. The additional testing shall be conducted under ambient environmental conditions. Only the location(s) that did not pass base LAT shall undergo testing. An aggregated 90/90 Upper Tolerance Limit (UTL) based on the 48 measurements (the six or seven measurements from the failed test with the 42 or 41 additional measurements) shall be calculated for the location(s). If the

UTL meets the requirement (i.e. 16.0mm for the crown and sides or 25.4 mm for front and back), the location shall be considered to have met the requirement. The lot shall be rejected if the UTL is above the requirement for the location.

Additionally, at most one 9mm complete penetration is be allowed during the additional testing. One complete penetration out of 68 total shots (26 shots from failed LAT plus 42 additional side or front shots) OR one complete penetration out of 67 total shots (26 shots from failed LAT plus 41 additional crown or back shots) is allowed. The lot shall be rejected with more than one complete penetration.

8 Overall Acceptance Criteria

8.1.1 Overall Acceptance Quality Level

Overall Acceptance Criteria is shown in Table VII.

Table VIII. LAT Overall Destructive Acceptance/Rejection Criteria

Lot Size # of Helmets Accept

(# helmets w/ defects)

Reject

(# helmets w/ defects)

91-150 17 1 2

151-280 19 1 2

281-500 19 1 2

501-1,200 26 2 3

1,201-3,200 34 3 4

9 Lot Disposition following LAT

a. Lot acceptance will be determined after testing and inspections have been completed and all data is received by the ECH Program Office. Test reports and results will be tracked through a test management system. For destructive lot acceptance tests, the facility conducting the testing will forward data to ATC for processing and analysis. ATC will then provide a final test report and data package to the ECH Program Office.

For non-destructive lot acceptance tests the vendor will provide a final report to the ECH Program Office. All final test reports will be uploaded to the test management system (currently PM-SPE’s SMARRTED system).

The Program Manager for Infantry Combat Equipment (PM-ICE) will designate graders who will be assigned to review the test reports. Once the reports are reviewed by all graders an automatic email notification of their acceptance or rejection will be sent to the Defense Contracting Management Agency (DCMA). DCMA will then notify the vendor for disposition of the lot. This process will be repeated for each lot acceptance test.

b. Data Assessment Conference. In the event of any failures or anomalies at LAT, the test lab will provide test results for adjudication. The results will be reviewed and the contractor will be required to take corrective action and submit a Failure Analysis and Corrective Action Report (FACAR). The Government will complete a review of the FACAR submitted and inform the vendor of the resulting disposition and any further actions required.

10 LAT Resource Summary

A detailed summary of samples required for testing based upon lot size is listed in Table IX.

Table IX. LAT Resource Summary for Normal Inspection

Lot Size

N o n -D estru ctiv e

D estru ctiv e

Minimum Number of Helmets

Required

Contingency

Samples Total Samples

91-150 8 17 25 3 28

151-280 13 19 32 3 35

281-500 20 19 39 3 42

501-1,200 31 26 57 4 61

1,201-3,200 51 34 85 4 89

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, TBD.