Attachment_J.2_MBP_QALI.pdf

Attachment J-2

Maritime Buoyant Plate (MBP) 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 plate.

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

Table 1 below describes pertinent paragraphs regarding end item visual and dimensional quality assurance requirements taken from the MBP purchase description. 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 re-inspection by the QAR, at the contractor’s expense.

Re-inspection 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 re-inspection shall be conducted at normal inspection level. If the original inspection was conducted at a tightened inspection level, the re-inspection 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.

TABLE 1. Requirements and Verifications

CHARACTERISTICS REQUIREMENT

PARAGRAPH

VERIFICATION

PARAGRAPH

Operational Requirements 3.6 4.6 Ease of Insertion 3.6.1 4.6.1 Weight 3.6.2 4.6.2 Dimensional measurements 3.6.3 4.6.3 Thickness 3.6.4 4.6.4 Color 3.6.5 4.6.5

Labels/markings 3.6 4.6.6 Armor Labeling 3.6.6. 4.6.6.1 Unique Identification (UID) 3.6.6.1 4.6.6.2

Health and Safety 3.6.7 4.6.7 Personal Hazard 3.6.7.1 4.6.7.1 Magnetic Influence 3.6.7.2 4.6.7.3

Ownership and Support 3.7 4.7 Durability 3.7.1 4.7.1