Att_6_-_PC_Gen_III_Carrier_FAT_Plan_Final_01312018.pdf

M67854-18-R-1309

First Article Test Plan

For

Plate Carrier Generation III

Version 1.0

2 Jan 2018

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

V1.1 Jan 2018 iii

Record of Change

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

FIRST ARTICLE TEST PLAN

PLATE CARRIER GEN III

1. Part I - System Introduction.

a. Mission Description. The Plate Carrier Generation III (PC Gen III) will assist Marines, Soldiers, and Sailors by providing body armor protection and load bearing capability as they close with and destroy the enemy through fire and maneuver. Missions include the entire range of military operations.

b. Measures of Effectiveness and Suitability. Table I lists the operational effectiveness and suitability required by the U.S. Marine Corps Plate Carrier Statement of Need (SON) dated 25 Nov 2008 and the Family of Body Armor Operational Requirements Document (FBA ORD) dated 27 March 2012.

Table I: PC Gen III Operational Capabilities

Name (measure) TPM Goal Requirement Document Scalable Include low profile vest Mobility Attribute Policy Fit 2nd percentile female Marineto 98th percentile male Marine Fit Attribute Policy

Ease of Use Capable of being donned and adjusted to fit in thirty seconds or less

FBA ORD

Mobility Not prevent a Marine from performing normal tasks to include employment of all infantry weapons

FBA ORD/PC SON

Pack Compatibility Must be capable of being worn with current load bearing equipment

FBA ORD/PC SON

Material Non-corrosive, dull/non-reflective FBA ORD Material Durability Fungus resistant and not degraded by water, salt water, petroleom, oil, and lubricant products

PC SON

Environmental Durability Functional in all climates under operational conditions

FBA ORD

Recovery Strap Must have one PC SON Infrared Not increase the infrared signature PC SON Flame Resistant Must be flame resistant PC SON Adjustable Must be adjustable PC SON Closure Mechanism Does not open or shift due to Marine's movement or the added weight of components

PC SON

Load Bearing Capability Must allow for attachment of pouches using the Pouch Attachment Ladder System (PALS)

PC SON

Quick Release Must have a quick release PC SON

c. System Description. 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). The PC Gen III provides the same level of direct fire protection when worn with hard armor inserts and provides the same area of coverage and increased ballistic performance for soft armor as compared to the legacy system. It provides increased mobility, improved fit, lighter weight, and additional modularity to support various mission sets. The PC Gen III includes a low profile vest and an integrated load bearing panel to support 03XX series Reconnaissance, 58XX series Military Police (MPs), and 35XX series Vehicle Crewman Military Occupational Specialties (MOS) at a 25% weight reduction compared to the legacy PC.

d. PC Gen III Carrier Components. The PC Gen III Carrier shall meet the design and performance requirements in the PC Gen III Detail Specification DTL7001A0029 (Reference 1) and patterns. The PC Gen III Carrier is composed:

1) PC Gen III Carrier System:

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

2) 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 Pocket Harness Shoulder Straps Tube Adapters Soft Armor Cummerbund Carrier

3) The PC Gen III Carrier System and components come in the following sizes:

PC Gen III System, 8 sizes: X-Small Short (XS-S), X-Small (XS), Small Short (SM-S), Small (SM), Small Long (SM-L), Medium (MD), Large (LG), X-Large (XL).

Outer Vest Rear, 8 Sizes: XS-S, XS, SM-S, SM, SM-L, MD, LG, XL

Outer Vest Front, 8 Sizes: XS-S, XS, SM-S, SM, SM-L, MD, LG, XL

Load Bearing Panel, 8 Sizes: XS-S, XS, SM-S, SM, SM-L, MD, LG, XL

Rear Cummerbund Adapter, One Size Inner Vest Rear, 8 Sizes: XS-S, XS, SM-S, SM, SM-L, MD, LG, XL

Inner Vest Front, 8 Sizes: XS-S, XS, SM-S, SM, SM-L, MD, LG, XL

Outer Cummerbund, 3 Sizes: SM, MD, LG Inner Cummerbund, 3 Sizes: SM, MD, LG Side Plate Pockets, 2 Sizes: 6x6, 6x8 Harness, 3 Sizes: SM, MD, LG Shoulder Straps, One Size Tube Adapters, One Size Soft Armor Cummerbund Carrier, 3 Sizes: SM, MD, LG

e. Critical Technical Parameters. The PC Gen III Detail Specification (Ref 1) specifies the technical requirements and associated evaluation criteria. PC Gen III Carrier requirements for First Article Test (FAT), associated evaluation criteria, and FAT article quantities are included in Appendix A.

2. Part II – Integrated FAT Program Summary – Management: The Program Manager Infantry Combat Equipment, Individual Armor Team (IAT) is responsible for providing oversight for all PC Gen III Test and Evaluation (T&E) events including FAT. The Team is responsible for establishing this FAT Event Design Plan (EDP), detailing required tests and associated sampling and test article criteria. This FAT EDP has been reviewed and approved by the T&E Working Integrated Product Team (WIPT).

For FAT, the T&E WIPT responsibilities include the review of final detail test plans and procedures, test protocols, test results and reports. The PC Gen III team and the T&E WIPT will be responsible for reviewing and adjudicating test issues and test results against the approved detailed FAT plans and test procedures. A listing of the organizational membership to the T&E WIPT including the associated responsibilities for each organization are further defined in the PC Gen III Systems Engineering Plan (SEP) (Ref 2) and the Charter for the Body Armor T&E

WIPT.

3. Part III - First Article Test and Evaluation Outline

a. Objectives.

(1) To verify performance of the PC Gen III Carrier against the PC Gen III Detail

Specification.

b. FAT and Evaluation. FAT will be conducted on representative production demonstration models and materials that are submitted by the contractor for production evaluation. To ensure minimum performance requirements are met, testing and verification will be in accordance with the approved PC Gen III Detail Specification (Ref 1) for FAT. PC Gen III Carrier requirements for FAT, associated evaluation criteria, and FAT test article quantities are provided in Appendix A. All contractor-submitted FAT test articles, including spares, will be shipped to Aberdeen Test Center (ATC) in Aberdeen, MD for storage until FAT is completed and the final FAT report is issued. All testing will be conducted by ATC but may include other Government laboratories. Once testing begins, FAT is planned to be completed within 60 days.

While testing is underway, ATC will make accommodations for IAT witnesses. There will be no Government Reference testing.

At the conclusion of FAT, ATC will provide FAT status of testing and preliminary FAT results for review to the IAT and T&E WIPT members in preparation for a Data Assessment Conference (DAC). Actions, findings and scoring decisions will be documented in the T&E WIPT DAC meeting minutes. The meeting minutes will then be forwarded to the IAT and T&E WIPT for review. After FAT is completed and the final ATC FAT report has been issued, at IAT direction, ATC will ship all test articles back to the appropriate submitting contractor.

1) Testing – FAT

a. Test Planning: Under an established SOW and based on this approved FAT Event Design Plan (EDP), ATC will develop a FAT non-ballistic detailed test plan that the T&E WIPT will review and approve. Testing will be in accordance with the PC Gen III Detail Specification as approved for FAT and in accordance with applicable standards.

b. Objectives: To verify that the PC Gen III submitted for the PC Gen III program meet the non-ballistic contractual specifications as outlined in the PC Gen III Detail Specification. Subset objectives to the overall non-ballistic objective are as follows.

1. Verify the test articles, upon delivery and prior to testing, are complete, undamaged, and ready for testing.

2. Verify the materials and hardware used are as specified in the Detail Specification and meet the desired performance parameters.

3. Verify each carrier component system meets the design requirements of the PC Gen III Detail Specification (i.e. pattern conformance, dimensional conformance, construction, weight).

4. Verify the system is constructed in accordance with the Detail Specification.

5. Verify the system’s functional integration of all the system component subsystems.

6. Verify the fungus resistance of the system

7. Verify the system matches the specified shade.

8. Verify the system meets the specified infrared reflectance requirements.

9. Verify the system operational performance capabilities (drag strap strength, buckle strength, quick release, adjustment, ESAPI/ESBI integration, compatibility with PALS, Resistance to POL/sweat/seawater, dull/non-reflective, and non-corrosive) meet the requirements specified in the Detail Specification.

10. Verify ownership and support requirements as specified in the PC Gen III Detail Specification (i.e. health/safety, toxicity, hazardous materials, use and care instructions, labels, UID, repair kits)

c. Execution: All testing will be conducted by ATC in accordance with the PC Gen

III Detail Specification as approved for FAT. All testing will be under the supervision of Government personnel and the PC Gen III team. IAT representative(s) will be present at the test events, as necessary.

d. Reporting: Under an established SOW, ATC will execute the approved FAT test plan and submit preliminary data, draft and final reports to the PC Gen III team on the results of the testing. Three calendar work days after testing is completed for any specific specification requirement, preliminary data from that testing will be submitted by ATC to the IAT for review.

A follow-on draft report will be submitted by ATC to the IAT for review and comment within 14 calendar days after completion of all testing and will be used to adjudicate any test result discrepancies. An overall final test report will be submitted by ATC to the IAT within 45 days after overall test completion. ATC is responsible for the test data in accordance with the criteria of the approved PC Gen III Detail Specification and associated spreadsheet found in Appendix A. If there are noted discrepancies between the DAC and the ATC report, the DAC will prepare a Memorandum for the Record to address the discrepancies.

4. Part IV – FAT and Evaluation Resource Summary.

a. Summary

Table II: Quantity of FAT Test Articles

Test Event

Finished Complete PC Gen

Cut and Unsewn Components

MOLLE

Panels

Raw Materials:

Fabric

Raw Materials:

Laminate, Raw Materials:

Webbings/Tape and Hook and

Hardware:

Buckles, Zippers, Threads

III

Systems

Foam, Stiffeners

Loop Fasteners etc.

FAT 16

(1 of each size in each color)

(1 end item component per each size in coyote only)

15” x 24”

(coyote only)

20 ft.

(of each cloth fabric in each required color)

12”x12” sheets of each material in each required color

60 ft.

(of each material in each required color)

10 (of each type of hardware in each required color)

1 spool (each type of thread in each require color)

1) Test Articles: Test articles will be considered production-representative models and/or production-representative components. Test articles that are considered production-representative Production models or components will be configured as a finished system or component according to the detailed FAT plans. Per the PC Gen III Detail Specification, the test articles considered production –representative systems or models are defined as:

a. Finished PC Gen III Systems: A representative production PC Gen

III with all components constructed and complete. One of each size in each required color (coyote and black).

b. Cut and Unsewn Components: A representative component that has been cut and not sewn in coyote only.

c. MOLLE Panels: A representative panel of the bartack/laser cut

MOLLE system in coyote only.

d. Raw Materials and Hardware: Materials and hardware that will be used in the final production end item in each required color.

2) Test Sites and Instrumentation: Test ranges/facilities to be used for each type of testing will be in accordance with the approved detailed FAT plans and other ATC Test Operating Procedures, and/or commercial standards. PM ICE has a current SOW with

ATC.

Appendix A: FAT PC Gen III Quantities and Allocation

O ut er V es t R ea r

(8 si ze s)

O ut er V es t F ro nt

(8 si ze s)

L oa d B ea ri ng P an el

(8 si ze s)

R ea r C um m er bu nd A da pt er

(1 si ze

In ne r V es t R ea r

(8 si ze s)

In ne r V es t F ro nt

(8 si ze s)

O ut er C um m er bu nd (3 si ze s)

In ne r C um m er bu nd (3 si ze s)

Si de

P la te P oc ke ts (2 si ze s)

H ar ne ss

(3 si ze s)

Sh ou ld er

S tr ap s ( siz e)

T ub e A da pt er s ( siz e)

So ft

A rm or C um m er bu nd

C ar ri er

(3 si ze s)

1 Material and Hardware Component Verification

Any material or hardware component not as specified or not in accordance with required performance.

Test/Visual Examination

Varied Materials and Components

See Paragraph

4.2.1 of PC Gen

III Detail Specification

2 Pattern Conformance Any major or minor defect or non-conformity constitutes a test failure.

Visual Examination

57 (1 cut/unsewn end item component per size)

8 8 8 1 8 8 3 3 2 3 1 1 3

3 End Item Dimensions Any major or minor defect or non-conformity constitutes a test failure.

Visual Examination

16 Finished Systems (2 of each size)

4 Weight Any weight over the specified max weight constitutes a test failure.

Test 16 Finished Systems (2 of each size)

5 Construction Any major or minor defect or non-conformity constitutes a test failure.

Visual Examination

16 Finished Systems (2 of each size)

6 MOLLE Attachment Testing

Any non-conformance to requirement constitutes a test failure.

Test/Visual Examination

3 MOLLE Attachment Sample Panels

7 Functional Integration Any non-conformance to requirement constitutes a test failure.

Demonstration 8 Finished Systems (1 each size)

8 Fungus Test Any non-conformance to requirement constitutes a test failure.

Test Varied Materials See Paragraph

4.2.1 of PC Gen III Detail

T es t N um be r

PC

G en

II

I R qm t

Pa ss

/F ai l C ri te ri a

V er ifi ca tio n

M et ho d

Sa m pl in g

R aw

M at er ia ls/ H ar dw ar e

Fi ni sh ed

P C

G en

II

I S ys te m (8 si ze s)

M O

L L

E A tta ch m en t S am pl e

Pa ne ls (1

5i nc h x in ch )C ut a

U ns ew n

C om po ne nt

(s iz es v ar ie d) er V es t R ea r

(8 si ze s)

O ut er V es t F ro nt

(8 si ze s)

L oa d B ea ri ng P an el

(8 si ze s)

R ea r C um m er bu nd A da pt er (1 si ze

In ne r V es t R ea r

(8 si ze s)

In ne r V es t F ro nt

(8 si ze s)

O ut er C um m er bu nd (3 si ze s)

In ne r C um m er bu nd (3 si ze s)

Si de

P la te P oc ke ts (2 si ze s)

H ar ne ss

(3 si ze s)

Sh ou ld er

S tr ap s ( siz e)

T ub e A da pt er s ( siz e)

So ft

A rm or C um m er bu nd C ar ri er (3 si ze s)

9 Shade Any non-conformance to requirement constitutes a test failure.

Visual Examination

8 Finished Systems (1 each size) 8

10 Infrared Reflectance Any non-conformance to requirement constitutes a test failure.

Test Varied Materials

See Paragraph

4.2.1 of PC Gen

III Detail Specification

11 Matching Any non-conformance to requirement constitutes a test failure.

Visual Examination

8 Finished Systems (1 each size) 8

Drag Strap Seam Strength

Any non-conformance to requirement constitutes a test failure. Test

2 Finished Outer Rear Carriers

2 Outer Rear

Carriers

13 Buckle Strength Any non-conformance to requirement constitutes a test failure.

Test 2 Male Buckles and 2

Female Buckles of each type

Buckles

See Paragraph

4.2.1 of PC Gen

III Detail Specification

Quick Release Mechanism Verification

Any non-conformance to requirement constitutes a test failure. Demonstration

8 Finished Systems (1 of each size) 8

15 Adjustment Any non-conformance to requirement constitutes a test failure.

Visual Examination/

Demonstration

8 Finished Systems (1 of each size)

16 ESAPI Insertion Any non-conformance to requirement constitutes a test failure. Demonstration

8 Finished Systems (1 of each size) 8

Compatibility with PALS Equipment

Any non-conformance to requirement constitutes a test failure. Demonstration

8 Finished System (1 of each size) 8

Resistance to POL, sweat, sea water

Any non-conformance to requirement constitutes a test failure. Test Varied Materials

See Paragraph

4.2.1 of PC Gen

III Detail Specification

Fi ni sh ed

P C

G en

II

I S ys te m (8 si ze s)

C ut ew n C om po es v ar ie d)

M O

L L

E A tta ch m en t S am pl e

Pa ne ls (1

5i nc h x in ch

R aw

M at er ia ls/ H ar dw ar e

T es t N um be r

PC

G en

II

I R qm t

Pa ss

/F ai l C ri te ri a

V er ifi ca tio n

M et ho d

Sa m pl in g er V es t R ea r

(8 si ze s)

O ut er V es t F ro nt

(8 si ze s)

L oa d B ea ri ng P an el

(8 si ze s)

R ea r C um m er bu nd A da pt

(1 ze

In ne r V es t R ea r

(8 si ze s)

In ne r V es t F ro nt

(8 si ze s)

O ut er C um m er bu nd (3 si ze s)

In ne r C um m er bu nd (3 si ze s)

Si de

P la te P oc ke ts (2 si ze s)

H ar ne ss

(3 si ze s)

Sh ou ld er

S tr ap s ( siz e)

T ub e A da pt er s ( siz e)

So ft

A rm or C um m er bu nd C ar ri

(3 ze s)

19 Health and Safety Any non-conformance to requirement constitutes a test failure. CoC NA

20 Toxicity Any non-conformance to requirement constitutes a test failure. CoC NA

21 Hazardous Materials Any non-conformance to requirement constitutes a test failure. CoC NA

Use and Care Instruction

Any non-conformance to requirement constitutes a test failure. Inspection

16 Finished Systems (2 of each size) 16

Size, Identification, and Instruction Label

Any non-conformance to requirement constitutes a test failure. Inspection

16 Finished Systems (2 of each size) 16

24 UID Any non-conformance to requirement constitutes a test failure.

Inspection 16 Finished Systems (2 of each size)

25 Repair Kits Any non-conformance to requirement constitutes a test failure.

Inspection 16 Finished Systems (2 of each size)

0 0 0

16 8 8 8 1 8 8 3 3 2 3 1 1 3 3

See Paragraph

4.2.1 of PC Gen

III Detail Specification

M O

L L

E A tta ch m en t S am pl e

Pa ne ls (1

5i nc h x in ch

R aw

M at er ia ls/ H ar dw ar e

Tests 3, 4, 5, 7, 9, 11, 12, 13, 14, 15, 16, 17, 22, 23, 24, 25 use the same finished systems Tests 12 uses components from the finished systems and should be conducted last.

Tests 1, 8, 10, 13, and 18 pull from the raw materials provided.

Fi ni sh ed

P C

G en

II

I S ys te m (8 si ze s)

C ut ew n C om po es v ar ie d)

Contingencies:

Total Quantities Needed:

Note that finished systems are used for multiple tests:

T es t N um be r

PC

G en

II

I R qm t

Pa ss

/F ai l C ri te ri a

V er ifi ca tio n

M et ho d

Sa m pl in g

References

1. Detail Specification, Plate Carrier Gen III, DTL 17001A0029, U.S. Marine Corps

(USMC) Systems Command, Program Manager (PM), Infantry Combat Equipment (ICE), 2200 Lester Street, Quantico, VA 22134-6050, January 2018.

2. Systems Engineering Plan, Plate Carrier Gen III, U.S. Marine Corps (USMC) Systems Command, Program Manager (PM), Infantry Combat Equipment (ICE), 2200 Lester Street, Quantico, VA 22314-6050, January 2018.