Attachment_J.2-NSFV_QALI_Rev_06_Aug_13.pdf

Attachment J-2

Navy Security Forces Vest (NSFV) Quality Assurance Letter of Instruction

Overview

The information provided in this Quality Assurance Letter of Instruction (QALI) is intended to be implemented by the Defense Contract Management Agency (DCMA) at the contractors manufacturing facility. This document stipulates the requirements and expectations of the PMO for production process monitoring, in-process material inspection, ballistic sampling procedures and finished end item evaluations. DCMA will develop and submit a Quality Assurance Surveillance Plan (QASP) to be coordinated with the PMO. The QASP shall describe the frequency and the types of process reviews and quality management system audits to be performed by the DCMA Quality Assurance Representative (QAR). The intent of the QASP is to ensure that contractors are meeting contract requirements in terms of utilizing production processes, methods, and materials approved by the PMO upon successful completion of First Article Testing (FAT).

Production Process Audits

DCMA shall conduct an initial assessment and document all manufacturing production processes at the beginning of the contract prior to full-rate production. Based on this initial assessment, DCMA will conduct periodic audits of the manufacturers production process to ensure that the processes utilized in the production of the approve First Article and Standard Sample items remain in effect during full rate production. The frequency of these reviews is outlined in the QASP.

In-Process Material Inspection Requirements

DCMA shall conduct in-process inspection of the following areas as stipulated in the

QASP.

Material Certifications

DCMA shall periodically verify that the manufacturer has documented evidence of raw material conformance inspections and certificates of conformance (CoCs) from raw material suppliers. Raw materials utilized in full-rate production shall be from the same source and of the same type and style of materials utilized in the approved FAT samples.

Ballistic Filler Material Traceability

DCMA shall periodically verify that the manufacturer has complete traceability of all ballistic filler material utilized in each finished lot back to the raw material supplier production lots and associated CoCs.

Ballistic Filler Material In-Process Inspection

DCMA shall periodically inspect cut ballistic filler parts for adherence to the contract patterns and dimensions. This shall be done by overlaying physical patterns of the ballistic filler components.

DCMA shall inspect the manufacturers ballistic filler quality records and verify that the contractor is conducting 100% inspection of all ballistic filler. DCMA shall also conduct periodic physical ply count audits of the cut ballistic filler components prior to being finished in a carrier.

Any cut part consisting of ballistic material found to be outside of approved dimensional tolerances or of incorrect ply count shall be removed from production and the manufacturer shall inspect 100% of all cut ballistic material. The manufacturer shall report to the government their findings of all inspected cut ballistic material.

Nonconforming cut ballistic material shall be segregated and removed from the production process.

Ballistic Lot Acceptance Test (LAT) Sampling Procedures

Finished end items shall be utilized in the test and evaluation of ballistic performance for each lot presented to the government. The lot size of finished end items dictates the quantity of items required for ballistic testing. Item sample quantities are found in the contract purchase description.

A form DD1222 shall accompany all finished end item samples sent for ballistic testing.

Ballistic testing shall be conducted at a mutually agreed upon commercial independent or government test laboratory.

Results of the ballistic testing shall be sent directly to the PMO’s technical point of contact for evaluation. Notification of recommendation to accept or reject the lot based on the results of the LAT shall be provided to the DCMA QAR from the PMO.

Notification of acceptance from the PMO is required prior to WAWF acceptance and release of shipment.

Finished End Item Visual and Dimensional Sampling Inspection Procedure

The following are the pertinent paragraphs regarding end item visual and dimensional quality assurance requirements taken from the NSFV purchase description and tables from Appendix B. In the event of a conflict between this document and the Purchase Description, the Purchase Description shall take precedence. Sampling procedures, tables and figures referenced can be found in ANSI/ASQ Z1.4-2008.

Required tools for inspection are:

-One data log per system -Metal ruler(s) -Metal flexible tape measure

Finished end item samples shall be randomly selected from a finished lot of complete systems and subject to visual and dimensional inspection. The quantity of samples required is dictated by a double sampling plan at inspection level S-3 and an AQL of 4.0 for majors and an AQL of 6.5 for minors. Inspection shall be conducted at a normal, tightened or reduced level as dictated by the Switching Procedures outlined below. The QAR and manufacturer must receive prior approval from the contracting authority prior to any of the switching procedures being invoked. Tables dictating sample size for the double sampling plans are attached to this document and can be found in ANSI/ASQ Z1.4-2008.

A data log is provided for End Item Defects and End Item Dimensional Examination.

One log shall be used to document the review of each system. The lot number, serial number and date of inspection shall be documented for each system inspected. For each major or minor defect found, the corresponding major or minor number will be written in the components respective column. Nonconformities shall be totaled by component.

The number of component types sampled shall be equal to the first sample size given by the plan. If the number of nonconformities, for a given component, found in the first sample is equal to or less than the first acceptable number, the lot or batch shall be considered acceptable. If the number of nonconformities, for a given component, found in the first sample is equal to or greater than the first rejection number, the associated components for that lot shall be considered non-acceptable. If the number of nonconformities, for a given component, found in the first sample is between the first acceptance and rejection numbers, a second sample of the size given by the plan, for that specific component, shall be inspected. The number of nonconformities found in the first and second samples shall be accumulated by component. If the cumulative number of nonconformities, for a given component, is equal to or greater than the second rejection number, the associated components for that lot shall be considered non-acceptable.

For components that are found to be non-acceptable, the contractor shall conduct 100% inspection of that component. Based on the severity of the non-conformity and direction by the government, those components will either be removed from the finished lot and replaced, or nonconformities corrected, prior to reinspection by the QAR, at the contractor’s expense.

Reinspection shall be conducted at the same inspection level that the original inspection was conducted under unless otherwise directed by the contracting authority. This means that if the original lot inspection was conducted at normal inspection level, the reinspection shall be conducted at normal inspection level. If the original inspection was conducted at a tightened inspection level, the reinspection shall be conducted at a tightened inspection level.

Switching Procedures

Normal inspection will be used at the start of inspection unless otherwise directed.

Normal, tightened or reduced inspection shall continue unchanged on successive lots except in cases where the switching procedures defined below require a change. The QAR and manufacturer must receive prior approval from the contracting authority prior to any of the switching procedures being invoked.

Normal to Tightened. When normal inspection is in effect, tightened inspection shall be instituted when 2 out of 5 consecutive lots (or a single lot at the Government’s sole discretion) have been non-acceptable on original inspection. (i.e., ignoring resubmitted lots or batches for this procedure.)

Tightened to Normal. When tightened inspection is in effect, normal inspection shall be instituted when 5 consecutive lots (or more at the Government’s sole discretion) have been considered acceptable on original inspection.

Normal to Reduced. When normal inspection is in effect, reduced inspection shall be instituted, at the Government’s sole discretion, provided that all of the following conditions are satisfied.

a. The preceding 10 lots have been on normal inspection and all have been accepted on original inspection; and

b. The total number of nonconforming units in the samples from the preceding 10 lots is equal to or less than the applicable limit number given in Table VIII of

ANSI/ASQ Z1.4-2003.

c. Production is at a steady rate; and

d. Reduced inspection is considered acceptable by the government.

Reduced to Normal. When reduced inspection is in effect, normal inspection shall be instituted if any lot is rejected.

Discontinuation of Inspection. If the cumulative number of lots not accepted in a sequence of consecutive lots on tightened inspection reaches five (5), inspection shall not be resumed until corrective action has been taken. Tightened inspection shall then resume.

Switching Sequence. A schematic diagram describing the sequence of application of the switching rules is shown in Figure 1 of ANSI/ASQ Z1.4-2003.

Finished End Item Visual Quality Assurance

TABLE II-B. End item defects (see 4.5.1).

Examine Description CLASSIFICATION1

Major Minor

1. Cloth Any hole, cut, or tear.

Any abrasion marks, broken or missing yarns, or multiple floats.

Any mend, dam or patch.

Any needle chews.

2. Webbing or Tape Any hole, cuts, tears or smash.

Not firmly and tightly woven, edges frayed or scalloped.

Multiple floats.

Abrasion mark, slub, broken end or pick.

Ends not fused as required.

3. Fastener Tape Any hole, cut or tear, hooks flattened, broken or missing, impairing function.

Stitched in the selvage area.

4. Seams and Stitching:

a) Open Seams ½ inch or less.

More than ½ inch.

NOTE: A seam shall be classified as an open seam when one or more stitches joining a seam are broken or when two or more consecutive skipped or runoff stitches occur.

b) Raw Edges More than ½ inch when securely caught in stitching.

NOTE: Raw edges not securely caught in stitching shall be classified as open seams.

c) Seam & Stitch Type Wrong seam or stitch type.

d) Stitch Tension Tension loose, resulting in loose bobbin or top thread.

Excessively tight, resulting in puckering of material.

e) Bartacks Any bartack omitted.

Any bartack not as specified or not in specified location.

Loose stitching, incomplete or broken.

f) Stitching Ends Not secured as specified. 211

g) Thread Breaks, Skipped Stitches, or Run-Offs

Not over-stitched as specified. 212

Note: Thread breaks or two or more consecutive skipped or run-off stitches not over-stitched shall be classified as an open seam.

5. Component & Assembly Any area of ballistic filler bunched. (i.e. Does not lie flat. 111 Any component part omitted or not as specified (unless otherwise classified herein.)

Needle chews.

Any mend, darn, patch, hole, splice or other unauthorized repair.

a) Location Markings Printed marking more than 1/32 inch in width or not covered by component part.

b) Label Missing, incorrect, or illegible.

c) Shade Individual components do not provide a good match to one another and the standard.

d) Plate Pocket Insert does not fit and cannot be secured into plate pocket. 117

6. End Item Dimensional Examination

a) Dimensional (overall) Smaller than nominal dimensions less applicable minus tolerance indicated but not smaller than nominal dimensions less twice the applicable minus tolerance.

Larger than nominal dimensional and applicable plus tolerance.

b) Component and Location Dimensions

Not within specified tolerance. 215

c) Stitch Margin or Gage Not within specified tolerance.

d) Box, Box-X and Stitching

Dimensions not within specified tolerance. 217

e) Hardware Not spaced within specified tolerance. 218

7. Size of Individual Ballistic Filler Assembly

Smaller than cutting pattern:

3/16 to 3/8 inch at any point around the periphery 2/3/

More than 3/8 inch at any point around the periphery 2/3/

1/8 inch up to 3/16 inch around entire periphery 3/

More than 3/16 inch around entire periphery 3/

Larger than cutting pattern by 3/8 inch or more at any point 2/3/

Minimum soft armor extending beyond edge of insert is not achieved.

1/The presence of a number designates either major or minor. The value of the number is for internal inspection purposes only.

2/ To be scored when condition exits for a length of more than 2 inches or if condition exists in several areas with an accumulated distance of 4 inches.

3/ The front filler or back filler individual components, as applicable shall be examined with the applicable cutting pattern centered on the filler components.

TABLE II-A. Maximum NSFV component weights, lbs. (see 3.5).

Finished Component

X-Small Small Medium Large X-Large XX- Large

XXX-

Large

Base Vest Assembly 7.87 8.42 9.51 10.65 11.85 13.07 14.17

Yoke and Collar Assembly

.90 .95 1.1 1.2 1.25 1.3 1.35

ESAPI 3.80 4.75 5.45 6.25 7.1 7.1 7.1

Total System Weight

16.37 18.87 21.51 24.35 27.30 28.57 29.72

TABLE III-A. Minimum ballistic panel area, in2 (see 3.5).

Ballistic Panel

X-Small Small Medium Large X-Large XX-Large XXX- Large

Front Panel

266.39 284.05 326.06 370.36 416.94 465.80 509.22

Back Panel

315.55 336.22 384.14 434.24 486.54 541.01 589.99

Yoke 61.56 64.46 70.32 76.24 82.24 88.30 94.44 Collar Wide

26.63 26.97 27.63 28.30 28.97 29.64 30.31

Collar Narrow

16.67 16.89 17.32 17.76 18.20 18.63 19.07

TABLE IV-A. Bartack (see 3.5.3.4).

Characteristic Stress points; All cloth Webbing hangers; Webbing

Length, in. (min) 3/8 inch ¾ inch ± 1/16 Holding strength, lb. (min.) 60 250

TABLE V-A. Base vest finished measurements, inches (see 3.5).*

Size Center Front Length

Front Width Center Back Length

Back Width

X-Small 16-3/4 29 18-1/2 20-1/2 Small 17 30 18-3/4 21-1/2 Medium 17-3/4 32 19-1/2 23-1/2 Large 18-1/2 34 20-1/4 25-1/2 X-Large 19-1/4 36 21 27-1/2 XX-Large 20 38 21-3/4 29-1/2 XXX-Large 20-1/2 40 22-1/4 31-1/2

Tolerance ± ½ inch ± ½ inch ± ½ inch ± ½ inch *See Paragraph 4.5.2.1 for measurement directions.

TABLE VI-A. Yoke and collar finished measurements, inches (see 3.5).* Size Collar Height Collar Length Center Back Yoke

Width X-Small 2 19-7/8 4 Small 2 20-1/8 4 Medium 2 20-1/2 4 Large 2 20-7/8 4 X-Large 2 21-1/4 4 XX-Large 2 21-5/8 4 XXX-Large 2 22 4

Tolerance ± ½ inch ± ½ inch ± ½ inch *See Paragraph 4.5.2.1 for measurement directions.

TABLE VII-A. Chest circumference for base vest outer shell label (see 3.6).

Size Chest Circumference (inches)

X-Small Below 33 Small 33-37 Medium 37-41 Large 41-45 X-Large 45-49 XX-Large 49-53 XXX-Large Above 53