Att_04_-19R1566_-_PC_Gen_III_Soft_Armor_LAT_Plan_Final_v2.pdf

Lot Acceptance Test (LAT) Plan

For

Plate Carrier Generation III Soft Armor

Version 1.0

Jan 2018

DISTRIBUTION STATEMENT D. Distribution authorized to Department of Defense (DoD) and US DoD contractors only; Administrative or Operational Use, 4 November 2016. Other requests shall be refened to the Commander, MARCORSYSCOM (Attn: PfM GCES - PM ICE)

2200 Lester Street, Quantico, VA 22134.

UNCLASSIFIED//FOR OFFICIAL USE ONLY

Approved by:

LtCol C.G. Madeline Program Manager, Infantry Combat Equipment

,o Jaf/1 I 8

Date Signed

UNCLASSIFIED//FOR OFFICIAL USE ONLY

ii

Vl.1

Jan 2018

Versfon

Record of Change

Date Paragraph Comm�n:t

UNCLASSIFIED//FOR OFFICIAL USE ONLY

iii

Approval

LOT ACCEPTANCE TEST (LAT) PLAN

PLATE CARRIER GEN III

1. (U) Scope. This document contains the Lot Acceptance Test (LAT) plan for the PC Gen III Soft Armor. 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 can'ier system and a soft atmor system and is often worn in conjunction with the Enhanced Small Aims Protective Inseiis (ESAPis). Unless otherwise stated herein, all requirements and verification methods shall be those prescribed in the contract and associated attachments, including PC Gen III Detail Specification.

2. (U) Classification. The PC Gen III soft armor is comprised of the following types:

Base Vest Inserts Side Plate Pocket Inseiis Cummerbund Inseiis

3. (U) Schedule of Sizes. This LAT plan is applicable for the following soft armor inseii sizes:

Base Vest Inseiis:

Side Plate Pocket Inseiis:

Cummerbund Inseiis:

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) 6x6 6x8 Small (SM) Medium (MD) Large (LG)

4. (U) 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 Aliicle Testing. Sampling and acceptance/rejection criteria shall be in accordance with this test plan. The lot will be accepted when it meets the minimum acceptance criteria for each individual requirement. This concept will ensure the PC Gen III program is responsive to the Office of the Secretary of Defense (OSD), Director of Operational Test and Evaluation (DOT &E) Soft Almor Ballistic Performance Guidelines while maintaining industry standards for Lot Acceptance is in accordance with ANSI/ASQ Zl .4.

4.1 (U) Sampling Selection. Lots shall be of a single type and size. Samples shall be randomly selected from all inserts 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 6, Table IV 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 IV in order to expedite the shipment of samples 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 (U//FOUO) Acceptance Criteria. In order for a lot to be considered acceptable, it shall meet all individual requirements (tests for specific individual requirements such as 9mm resistance to penetration and flexibility).

4.2.1 (U//FOUO) Individual Requirement Acceptance Criteria. The minimum acceptance criteria for the individual requirements are based on the number of inse1i performance failures for that requirement. Individual requirement accept/reject criteria are based on OSD DOT &E guidelines and cuffent soft aimor program acceptance criteria.

4.3 (U) Test Events.

4.3 .1 (U) Destructive Testing. The entire inse1i sample cannot be tested for all requirements.

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

4.3.2 (U) Non-Destructive Testing. The entire selected sample will be tested for all non-ballistic requirements prior to destructive testing.

4.4 (U) 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 Destructive Ballistic Testing (17-grain Certified Ballistic

V50, 9mm RTP/BFD, 9mm Laboratory1

V50), Areal Density Non-Destructive Pattern Confmmance, Contractor with DCMA

Dimensional and Visual witness Inspection, Area of Coverage, Thickness Flexibility, Functional Integration, Labels

1Facilities chosen by the contractor must be capable of accurately obtaining and documenting the required data of this test plan.

(U)

4.5 (U) Standard Ambient Conditions. All examinations, inspections, and testing shall be conducted in standard ambient conditions of 68°F ( + I0°F)/20°C ( +5 .6°C) and a relative humidity (RH) of 50% (+20%) and site atmospheric pressure, unless otherwise specified.

Additionally, test items shall be stored in standard ambient conditions for a minimum of 24 hours before testing, unless otherwise specified.

4.6 (U) Retesting. Examinations, inspections, and testing shall be conducted only once. If the test was conducted incoTI'ectly (not in accordance with the requirements), retesting shall be allowed. The test repmi shall repmi both original test and the retest results along with a detailed explanation as to what was inco11'ect in the original test. 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 Ce1iification of Compliance Items. The contractor shall deliver the Ce1iification of Compliance (CoC) in accordance with the contract. The CoC will address each of the requirements and ce1iify that the materials and manufacturing processes have not changed since First Aliicle 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 Verification Lot Acceptance

Paragraph Paragraph Test

Cloth Ballistic Inse1i Cover 3.2.5 4.5 1/

Ballistic Thread 3.2.16 4.5 1/

Unique Identification 3.8.7 4.11.7 1/

1/ Ce1iification of compliance shall be provided ce1iifying that the design and materials of the soft annor 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.

(U)

6. (U) Requirements and Verifications for Non-Destructive Items. Inse1is for Non Destructive testing will be chosen at random from the lot. The random selection shall be done prior to initiating a LAT using serial numbers provided by the contractors. Items requiring ce1iificate of confmmance will be submitted in accordance with the contract statement of work.

Table III lists the requirements for non-destructive characteristics.

VI.I

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

Lot Major/Minor

Requirement Verification Acceptance Classification for Characteristic

Paragraph Paragraph Test Accept/Reject

Criteria 1/

Maj or/Minor (see

Patterns 3.3.1 4.7.1 X 2/ Table:XXV, section 4.7.2)

Maj or/Minor ( see

Soft Almor Dimensional and 3.3.2.4 4.7.2 X 2/ Table XXV, Visual Inspection section 4.7.2)

Maj or/Minor ( see

Minimum Area of Coverage 3.3.2.2 4.7.3 X 2/ Table:XXV, section 4. 7.2)

Removable Ballistic Inse1i 3.6.1 4.9.1 X 2/ Major

Thickness 3.6.3 4.9.3 X /2 Major

Flexibility 3.6.4 4.9.4 X 2/ Major

Functional Integration 3.6.5 4.9.5 x 2/ Major

Label 3.6.6 4.7.2 X 2/ Critical

1/ An "x" in the column designates that the test is perfmmed. Sampling ratio is specified in Table

IV.

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

(U)

(U) All of the non-destructive inspections 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.

(U) 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 - Non-Destructive

Lot Size 1/ ANSI Zl.4 Quantity Accept# Reject# Basis Tested Minor Minor

Defects 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 base vest systems is comprised of 2 base vest inserts per base vest system (e.g. A lot of 26 base vest systems is comprised of 52 base vest inserts).

Component set lots (side plate pocket inserts or cummerbund inserts) are comprised of 2 inserts per set ( e.g. a lot of 26 side plate pocket component sets is comprised of 52 side plate pocket inserts).

(U)

7. (U) Requirements and Verifications for Destructive Testing. Once having passed non destructive testing, the selected inserts and additional required inserts shall be subjected to 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 base vest systems or Table VII for component set systems.

Table V: Requirements and Verifications for Destructive Inspection Characteristics

Characteristic Requirement Verification Lot Acceptance

Paragraph Paragraph Test

Areal Density 3.6.2 4.9.2 x2/

Fragmentation Protection: 3.7.1: 4.10 x2/ l 7gr FSP V50 Table XV-E 4.10.7

Handgun Protection: 3.7.2 4.10 X 2/ 9mm, V50, Dry Table XVI-A 4.10.7 9mm VO, Dry/BFD Table XVI-C 4.10.9 1/ An "x" in the column designates that the test is performed. Required number of inserts is provided in Table VI for base vest systems and Table VII for components.

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

(U)

(U) All of the ballistic requirements and verifications utilize pass/fail criteria. If any of the individual requirement criteria is not met when tested as specified then the lot is rejected. Areal density measurements shall be made on un-sewn shoot packs. For lots of base vest systems, consisting of 2 base vest inserts, Table VI shall be used. For lots of component sets, consisting of 2 side plate pocket inse1is or cummerbund inseiis, Table VII shall be used.

Table VI: Base Vest System Test Sample Selection Matrix Number of Tests (Number of test inserts per threat) Contingency Total

Lot Size 1/ VO, 9mm2/ Inserts inserts vso, VS0,9mm required XS-S, All other

17 gr (Dry) SM-S sizes 3/

26 to 150 2 2 7 6 4 14

151 to 1200 4 4 9 8 6 22

1201 to 3200 6 6 11 10 8 30

1/ Lot Size is comprised of base vest systems which consists of 2 base vest inse1is per base vest system ( e.g. A lot of 26 base vest systems is comprised of 52 base vest inse1is).

2/ The 9mm VO test tests two requirements: 9mm Resistance to Penetration (VO) and the Back Face Deformation. Criteria for both tests are provided in section 3.7.2 Table

IV-C.

3/ For XS-Shmi and SM-Shmi inse1is, one additional 9mm VO test shall be required due to the small size of the inse1is. This additional insert will be pulled from the contingency inse1is and the total number of inse1is required shall remain the same as other sizes.

(Q//FOUO)

T bl VII C a e : omponen tS tT tS e es l S lf M t' amp e e ec 10n a nx Number of Test Samples

VSO Tests per Lot Size 1/ Required for 17 gr. VSO component 2/ Cummerbund I Side Plate Pocket

Insert

26to 150 4

151 to 1200 8

1201 to 3200 12

Insert

1/ Lot size is comprised of component sets which consists of 2 inserts per set ( e.g. A lot of 26 component sets is comprised of 52 base vest inserts).

2/ Multiple test inserts may be necessary to calculate V50. If these requirements are not met using the first inse1i, subsequent inse1is may be used and combined until the number of valid data points is reached.

(U//FOUO)

(U//FOUO) If a LAT fails the BFD UTL requirement, additional measurements shall be used to provide a larger sample size to recalculate the BFD UTL. If the BFD UTL is met with the larger sample size, the lot can be accepted. If the BFD UTL is not met with the larger sample size, the lot will be rejected.

8. (U) Lot Disposition following LAT.

a. (U) Lot acceptance will be determined after testing and inspections have been completed and all data is received by the PC Gen III Program Office. For destructive lot acceptance tests, the facility conducting the testing will forward data and results to the PC Gen III Program Office. For non-destructive lot acceptance tests the vendor will provide a final rep01i to 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. (U) 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 coffective action and submit a Failure Analysis and Corrective Action Rep01i (F ACAR). The Government will complete a review of the F ACAR submitted and inform the vendor of the resulting disposition and any further actions required.