Att_5_-_PC_Gen_III_Carrier_LAT_Plan_Final_01312018.pdf

M67854-18-R-1309

Lot Acceptance Test (LAT) Plan

For

Plate Carrier Generation III

Version 1.0

Jan 2018

DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.

V1.1 iii

Record of Change

Version Date Paragraph Comment Approval V1.1 Jan 2018 Final PM

LOT ACCEPTANCE TEST (LAT) PLAN

PLATE CARRIER GEN III

1. Scope. This document contains the Lot Acceptance Test (LAT) plan for the PC Gen III Carrier. The PC Gen III is a body armor system consisting of a base vest and modular components for tailoring protection levels to defeat multiple ballistic hazards across the battlefield continuum and to manage armor weight. The PC Gen III is comprised of a carrier system and a soft armor system and is often worn in conjunction with the Enhanced Small Arms Protective Inserts (ESAPIs). Unless otherwise stated herein, all requirements and verification methods shall be those prescribed by the contract and associated attachments, including PC Gen III Detail Specification.

2. Classification. The PC Gen III is comprised of the following types:

PC Gen III System: Fully assembled system comprised of the

Outer Vest Assembly (outer vest rear, outer vest front, load bearing panel, rear cummerbund adapter, 2 shoulder straps, all buckles and hardware)

Inner Vest Assembly (inner vest rear, inner vest front) Outer Cummerbund Assembly (2 outer cummerbunds, 2 tube adapters) Inner Cummerbund Assembly (2 inner cummerbunds) Side Plate Pockets (2 side plate pockets) Harness Individual Repair Kit Use and Care Instruction Card Integrated Soft Armor Inserts (2 base vest inserts, 2 side plate pocket inserts)

Components: Outer Vest Rear Outer Vest Front Load Bearing Panel Rear Cummerbund Adapter Inner Vest Rear Inner Vest Front Outer Cummerbund Inner Cummerbund Side Plate Pockets Harness Shoulder Straps Tube Adapters Soft Armor Cummerbund Carrier

3. Schedule of Sizes. This LAT plan is applicable for the following system and component sizes:

PC Gen III System: X-Small Short (XS-S)

X-Small (XS) Small Short (SM-S) Small Long (SM-L) Small (SM) Medium (MD) Large (LG) X-Large (XL) Outer Vest Rear and Front: X-Small Short (XS-S) X-Small (XS) Small Short (SM-S) Small Long (SM-L) Small (SM) Medium (MD) Large (LG) X-Large (XL) Inner Vest Rear and Front: X-Small Short (XS-S) X-Small (XS) Small Short (SM-S) Small Long (SM-L) Small (SM) Medium (MD) Large (LG) X-Large (XL) Load Bearing Panel: X-Small Short (XS-S) X-Small (XS) Small Short (SM-S) Small Long (SM-L) Small (SM) Medium (MD) Large (LG) X-Large (XL) Side Plate Pocket Inserts: 6x6 6x8 Outer Cummerbund: Small (SM) Medium (MD) Large (LG) Inner Cummerbund: Small (SM) Medium (MD) Large (LG) Soft Armor Cummerbund: Small (SM) Medium (MD) Large (LG) Harness: Small (SM) Medium (MD) Large (LG) Rear Cummerbund Adapter: One Size

Shoulder Straps: One Size Tube Adapter: One Size Repair Kit: One Size

4. Lot Acceptance Testing Concept. The Lot Acceptance Testing (LAT) will ensure the contractor provides a consistent product in accordance with the PC Gen III Detail Specification 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 the minimum requirements for each individual requirement. This concept will ensure the PC Gen III program is consistent with Program Office requirements and that Lot Acceptance is in accordance with

ANSI/ASQ Z1.4.

4.1 Sampling Selection. Lots shall be of a single type and size. Samples shall be randomly selected from all items within the lot. The random selection shall be done by the Government.

Paragraph 6, Table IV indicates the number of samples to be selected for LAT.

4.2 Acceptance Criteria. In order for a lot to be considered acceptable, it shall meet all individual requirements (tests for specific individual requirements such as dimensional conformance and shade).

4.2.1 Individual Requirement Acceptance Criteria. The minimum acceptance criteria for the individual requirements are based on the number of defects for that requirement. Individual requirement accept/reject criteria are based on current body armor program acceptance criteria.

4.3 Test Events.

4.3.1 Inspection/Demonstration Verification. The entire selected sample will be tested for all inspection and demonstration verifications prior to lot acceptance.

4.3.1.1 Integration of Soft Armor. Integration of soft armor can occur prior to or after LAT as makes the most sense for production.

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

(U) Table I: Testing Facilities Requirement US Marine Corps Non-Destructive Materials and

Components, Design, Construction, Operational Performance, Support and Ownership

Contractor with DCMA witness

4.5 Retesting. Examinations, inspections, and testing shall be conducted only once. If the test was conducted incorrectly (not in accordance with the requirements), retesting shall be allowed.

In cases where the test was conducted incorrectly but the item failed the test, retesting is only allowed with the express permission of the Program Office.

5. (U) 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 First Article Test (FAT). The lot shall be accepted in accordance with this paragraph (see Table II) when the Government receives the CoC.

(U) Table II: Requirements and Verifications for Certification of Compliance Items

Characteristic Requirement Paragraph

Verification Paragraph

Lot Acceptance

Test

Material and Components 3.2 4.5

Cloth, Outer Shell 3.2.1 4.5 1/

Cloth, Plate Pocket 3.2.2 4.5 1/

Cloth, Interior Liner 3.2.3 4.5 1/

Cloth, Foam Pockets and Shoulder Covers 3.2.4 4.5 1/

Cloth Ballistic Panel Cover 3.2.5 4.5 1/

Outer Laminate Material 3.2.6 4.5 1/

Cloth, Cummerbund Shroud 3.2.7 4.5 1/

Webbing and Tapes 3.2.8 4.5 1/

Webbing, Elastic 3.2.9 4.5 1/

Fasteners, Hook and Loop 3.2.10 4.5 1/

Fasteners, Hook and Loop Low Profile 3.2.11 4.5 1/

Fasteners, One Wrap 3.2.12 4.5 1/

Foam 3.2.13 4.5 1/

Stiffener 3.2.14 4.5 1/

Non-Ballistic Thread 3.2.15 4.5 1/

Ballistic Thread 3.2.16 4.5 1/

Male Buckle 3.2.17 4.5 1/

Female Buckle 3.2.18 4.5 1/

Male Repairable Buckle 3.2.19 4.5 1/

Female Repairable Buckle 3.2.20 4.5 1/

Tension Lock 3.2.21 4.5 1/

Tension Lock Repairable 3.2.22 4.5 1/

Loop 3.2.23 4.5 1/

Slider 3.2.24 4.5 1/

Male Quick Release Fastener 3.2.25 4.5 1/

Female Quick Release Fastener 3.2.26 4.5 1/

Male Quick Release Fastener Repairable 3.2.27 4.5 1/

Female Quick Release Fastener Repairable 3.3.28 4.5 1/

Slide Fastener 3.2.29 4.5 1/

Carrier Operational Performance Requirements

3.5 4.8 1/

Fungus Resistance 3.5.2 4.8.2 1/

Shade 3.5.3 4.8.3 1/

Infrared Reflectance 3.5.4 4.8.4 1/

Matching 3.5.5 4.8.5 1/

Drag Strap 3.5.6 4.8.6 1/

Buckle Strength 3.5.7 4.8.7 1/

Adjustment 3.5.9 4.8.9 1/

Resistance to POL, sweat, and sea water 3.5.12 4.8.13 1/

Support and Ownership 3.8 4.11

Health and Safety 3.8.2 4.11.2 1/

Toxicity 3.8.3 4.11.3 1/

Hazardous Materials 3.8.4 4.11.4 1/

1/ Certification of compliance shall be provided certifying that the design and materials of the PC Gen III have not changed since approval of FAT.

The Government reserves the right to inspect or test such items to verify the validity of the certification.

6. (U) Inspections and Demonstration Verifications. Carriers or components for inspection and demonstration verification will be chosen at random from the lot. Items requiring certificate of conformance will be submitted in accordance with the contract Statement of Work. Table III lists the requirements for carrier design and construction characteristics.

(U) Table III: Requirements and Verifications for Non-Destructive Test Characteristics

Characteristic Requirement Paragraph

Verification Paragraph

Lot Acceptance

Test

Major/Minor Designation

Design 3.3 4.6

Patterns 3.3.1 4.6.1 x 2/ Major/Minor

(See Table XVIII, Section 4.6.2)

Subsystems 3.3.2 4.6 x 2/ Major/Minor

(See Table XVIII, Section 4.6.2)

Carrier Finished Dimensions 3.3.2.3 4.6.2 x 2/

Major/Minor (See Table XVIII, Section 4.6.2) Construction 3.4 4.6

Hook and Loop Fastener 3.4.1 4.6.4 x 2/

Major/Minor (See Table XIX, section 4.6.4)

Seams and Stitching 3.4.2 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Automatic Stitching 3.4.3 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Bartack 3.4.4 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Laser Cut Slits 3.4.5 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Bartack Alignment for PALS 3.4.6 4.6.4 x 2/

Major/Minor (See Table XIX, section 4.6.4)

Buttonholes 3.4.7 4.6.4 x /2 Major/Minor

(See Table XIX, section 4.6.4)

Binding 3.4.8 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Component and Hardware Location 3.4.9 4.6.4 x 2/

Major/Minor (See Table XIX, section 4.6.4) Component and Hardware Attachment

3.4.10 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Reinforcement Stitching 3.4.11 4.6.4 x 2/

Major/Minor (See Table XIX, section 4.6.4)

Fabric 3.4.12 4.6.4 x 2/ Major/Minor

(See Table XIX, section 4.6.4)

Carrier Operational Performance Requirements

3.5 4.8

Functional Integration 3.5.1 4.8.1 x 2/ Major

Quick Release Mechanism 3.5.8 4.8.8 x 2/ Major

Adjustment 3.5.9 4.8.9 x 2/ Major

E-SAPI/ESBI

Integration 3.5.10 4.8.10,4.8.11 x 2/ Major

Compatibility with PALS 3.5.11 4.8.12 x 2/ Major

Dull/Non-reflective 3.5.13 4.6.4 x 2/ Minor

Non-corrosive 3.5.14 4.6.4 x 2/ Minor Support and Ownership 3.8 4.11

Use & Care Instruction 3.8.5 4.11.5 x 2/ Minor

Labels 3.8.6 4.6.4 x 2/ Critical Unique Identification 3.8.7 4.6.4 x 2/ Minor

Repair Kit 3.8.8 4.6.4 x 2/ Critical 1/ An “x” in the column designates that the test is performed. Sampling ratio is specified in Table.

2/ Test in accordance with applicable paragraph in Detail Specification.

All of the individual verifications shall utilize the following accept/reject criteria.

a) One or more major defects constitutes a rejection of the lot.

b) A minor defect rate higher than allowed by Table IV constitutes a rejection of the lot.

c) If a critical defect is found during inspection, the lot shall be 100% inspected for the critical nonconformities and corrected or replaced at the discretion of the Government.

The quantity of samples to be inspected and the accept/reject criteria for minor defects is provided in Table IV.

Table IV: Single Sampling for Normal Inspection – Inspection/Demonstration

7. Lot Disposition following LAT.

a. Lot acceptance will be determined after testing and inspections have been completed and all data is received by the PC Gen III Program Office. Once reports are reviewed, the project engineer will send an email notification of their acceptance or rejection to 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, Lot Size 1/ ANSI Z1.4 Basis

Quantity Tested

Accept # Minor

Defects

Reject # Minor

Defects

26 – 150 S-3, AQL 4, C 3 0 1

151-1200 S-3, AQL 4, E 13 1 2

1201-3200 S-3, AQL 4, E 13 1 2

1/ Lot Size for PC Gen III systems is comprised of complete systems. Component lots are comprised of individual component pieces.

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 and inform the vendor of the resulting disposition and any further actions required.