AQAR August 2021.pdf

Revision 1 dated August 2021

DLA TROOP SUPPORT

CLOTHING & TEXTILES

ADDITIONAL QUALITY

ASSURANCE REQUIREMENTS

(formerly 4155.3)

DLA-Troop Support, 700 Robbins Ave, Philadelphia, PA 19111-5096

Distribution statement A. Approved for public release: distribution unlimited.

TABLE OF CONTENTS

1. GENERAL REQUIREMENTS Pages 6-9

1.1. Contractor’s Obligation to Obtain Technical Data

1.2. Contractor’s Obligation for Testing

1.3. Quality System Requirements

1.3.1. Standard Inspection Clause

1.3.2. Higher Level Inspection Contract Quality Clause

1.4. Product Demonstration Models (PDMs)

1.5. First Article

1.6. Production Testing

1.6.1. Identification of Testing Sites

1.6.2. Certification of Testing Sites

1.6.2.1. Approval

1.6.2.2. Disapproval

1.7. Government Furnished Material

1.8. Government Furnished Equipment

1.9. Government Furnished Property

1.10. Toxicity Requirements

2. INSPECTION REQUIREMENTS Pages 10-13

2.1. Lot Formation

2.1.1. Fabric Lot

2.1.1.1 Physical Testing Sampling Plan

2.1.2. Component Lot

2.1.3. Manufactured End Item Lot

2.1.3.1. Treated End Item Lot

2.1.3.2. Combined Manufactured Lots in Treated Lot

2.1.3.3. Multiple Treated Lots from a Manufactured Lot

2.2. Lot Numbering

TABLE OF CONTENTS, CONTINUED

2.2.1. Serialization

2.2.2. Traceability

2.3. Lot Integrity

2.4. Presentation of Lots

2.4.1. Quality Assurance

2.4.2. Side-by-Side Sampling

2.4.3. ANSI ACQ Z 1.4 (Switching Rules)

3. QUALITY TESTING REQUIREMENTS Pages 13-20

3.1. Certified Test Reports

3.1.1. Completion of DD Form 1222

3.1.1.1. Multiple Contractors

3.1.2. Test Report Data

3.1.3. Certificate of Compliance (CoC) Submission

3.2. Government Acceptance Testing

3.2.1. Shade Evaluation

3.2.1.1. Sampling

3.2.1.2. Submission

3.2.1.3. Shipment of Shade Evaluation Lots

3.2.1.4. No Shade Clause in Contract

3.2.2. Near Infrared Reflectance (nIR)

3.2.3. Production Lot Testing

3.2.4. Verification Testing

3.3. Government Contractor Testing

3.3.1. Notification

3.3.2. Contractor Furnished Material (CFM)

3.3.3. Defective Government Furnished Material

3.3.4. Correlation Testing

TABLE OF CONTENTS, CONTINUED

3.4. Non-Conforming Material

3.4.1. Waiver Process

3.4.1.1. Resubmitted Lots

3.4.1.2. Tightened Inspection

3.4.2. Corrective Action Plan CAP Process

4. FINAL EXAMINATION Page 20-21

4.1. Contractor’s Obligation for Examination

4.2. Presentation of End Item Lots

4.3. Product Acceptance and Release

5. FORMS Page 21-40

5.1. DLA Form 6005 Laboratory Testing Capabilities Survey

5.2. DD Form 1222 for Source Sampling

5.3. DD Form 1222 for Shade

5.4. DD Form 250 Material Inspection and Receiving Report

5.5. DLA Form 6004 Clothing & Textiles Laboratory Test Report and Instructions

5.6. Lab Report Sample

5.7. Letter of Exception for DCMA Stamps

5.8. Certificate of Compliance

5.9. DLA Form 506 Certificate of Deficient Government Furnished Material

5.10. DD Form 1694 Waiver Request

5.11. DD Form 1222 for Correlation Testing

5.12. Instructions for Submitting a DD Form 1222

6. REFERENCES Page 41

7. GLOSSARY OF ACRONYMS Page 42

8. ANNEX A Page 43-45

1. GENERAL REQUIREMENTS

1.1. Contractor’s Obligation to Obtain Technical Data. Offeror shall submit request for any technical data by utilizing the C&T portal; see Internet Resources for more information.

1.2. Contractor’s Obligation for Testing. The prime contractor is responsible to ensure all tests are performed as required by the contract. Testing shall take place on every lot of each contractor furnished material, or each shipment or lot of end items as applicable. Testing shall be performed by an authorized test facility as disclosed and cited on the active contract.

1.3. Quality System Requirements. The extent of contract quality requirements, including contractor inspection, required under a contract is based upon the classification of the contract item as determined by its technical description, its complexity, and the criticality of its application.

(a) Technical description.

(1) Commercial, per FAR 2.101 definition of commercial items.

(2) Military-Federal, all other items that do not meet the FAR 2.101 definition of commercial items.

(b) Complexity.

(1) Complex items have quality characteristics, not wholly visible in the end item, for which contractual conformance must be established progressively through precise measurements, tests, and controls applied during purchasing, manufacturing, performance, assembly, and functional operation either as an individual item or in conjunction with other items.

(2) Noncomplex items have quality characteristics for which simple measurement and test of the end item are sufficient to determine conformance to contract requirements.

(c) Criticality.

(1) A critical application item, which includes critical safety items, is any item containing a critical characteristic whose failure, malfunction, or absence may cause a catastrophic or critical failure resulting in loss or serious damage to a weapon or end item, unacceptable risk of personal injury, loss of life, or jeopardize a vital agency mission.

(2) A noncritical application is any other application.

1.3.1. Standard Inspection Clause FAR 52.246-2 requires the contractor to 1) provide and maintain an inspection system that is acceptable to the Government; 2) Give the Government the right to make inspections and tests while work is in process; and 3) Require the contractor to keep complete, and make available to the Government, records of its inspection work. Refer to FAR clause for the complete text.

1.3.2. Higher Level Contract Quality Clause FAR 52.246-11 requires the contractor to include applicable requirements of the higher-level quality standard(s) and the requirement to flow down such standards, as applicable, to lower-tier subcontracts, in

(a) Any subcontract for critical and complex items or

(b) When the technical requirements of a subcontract require:

(1) Control of such things as design, work operations, in-process control, testing, and inspection or

(2) Attention to such factors as organization, planning, work instructions, documentation control, and advanced metrology.

Refer to the FAR clause for the complete text.

1.4. Product Demonstration Models. Product Demonstration Models (PDMs) are sample(s) of the item required by the solicitation that are submitted as part of an offeror's technical proposal. The PDM permits examination of the offered item for the purpose of determining quality of workmanship and conformance to performance requirements. It also affords technical evaluators an opportunity to observe specific features or alternative approaches.

Contractors should request the most recent revision of the specification PD/patterns through the C&T portal. See Internet Resources for web address.

Offeror shall review PDM evaluation criteria stated in the solicitation to ensure compliance. Prior to PDM submittal, if an offeror has a question or notices a discrepancy in the technical requirements between the written documentation and the pattern, or a drawing, or between two written requirements, or any other component of the technical data package, they should contact the contracting officer for resolution.

The PDM shall be an exact match to all the specific requirements in the contract and technical data and shall be in strict accordance with the government provided pattern with no deviations in design or manufacturing processes. Deviations from the pattern or technical documents will put the contractor at risk for an unfavorable PDM rating.

Offerors must write a letter that accompanies their PDM submission when an alternate material is used during the construction of the PDM. If no letter is provided, and alternate materials are used during the construction of the PDM, the technical evaluation may be adversely affected as the evaluator may not be able to determine if the offeror understands what materials are required.

Offerors must select potential suppliers of the component materials that are Berry compliant and have supporting documentation. See Internet Resources for more information. The Offeror is responsible to ensure that offers reach the Government office designated in the solicitation on time. Successful awardees shall review PDM comments and take corrective actions as required prior to production.

1.5. First Article. First Article Testing (FAT) is the testing of items submitted by a contractor prior to regular production on a contract or purchase order, followed by the preparation and evaluation of test reports. The purpose of FAT and approval is to ensure that the contractor can furnish a product that meets the contract's technical and quality assurance requirements, and therefore minimizes the risks for both the contractor and the Government.

When a First Article is required, the contractor’s notification letter must be submitted to the Procuring Contracting Officer with a copy submitted to the cognizant quality assurance element of the Contract Administration Office. Contracts requiring a First Article shall specify quantity of samples required, testing requirements, and the test location/laboratory the First Article shall be submitted.

Approval of the First Article does not relieve the contractor from meeting any of the contract requirements. Change to the manufacturer’s design, materials, process, or place of performance may require a new First Article to be submitted for evaluation of either the full range of requirements or a limited number as determined by the Contracting Officer in conjunction with the Product Specialist and Engineering Support Activity.

1.6. Production Testing. Production may not commence until authorized by the Contracting Officer. Production Testing occurs after First Article Testing has passed and/or production has been authorized in writing by the Contracting Officer. If not previously identified, the contractor must utilize an approved laboratory for testing as outlined below in section 1.6.1. If End Item and Component Lots are required by the contract to be presented to the Government prior to acceptance, the vendor will notify DLA Troop Support that an End Item or Component Lot is available for Production Testing. The entire lot must be complete and made available to the Government on the date stated for inspection. If a lot is incomplete or partially unavailable, the Government will not perform inspection of the lot. (See section 2.1 for more information on Lot Formation). Testing shall be in accordance with contract requirements.

1.6.1. Identification of Testing Sites. Unless the contract mandates a Government laboratory be used to conduct testing, the prime contractor shall identify all testing sites that will perform any test required by the terms of the contract, including end item testing, in accordance with contract clause “Identification of Qualified Laboratory and Source Sampling”. Any laboratory proposed by the contractor is subject to the approval of the contracting officer. Testing facilities shall be subject to on-site witnessing of testing by the Government. The use of a laboratory previously approved by the Government is not a guarantee that testing will be performed properly, nor does it relieve a contractor from the contractual obligation to present conforming supplies accompanied by true, accurate, and valid test results.

1.6.2. Certification of Testing Sites. The prime contractor shall identify a technical point of contact for the testing site and provide current contact information. The prime contractor should alert the technical point of contact that the certification process has begun. A current ISO 17025 accreditation whose scope encompasses the contractual testing or equivalent will be accepted.

In the absence of an appropriate ISO 17025 accreditation, the DLA Product Test

Center (DLA-PTC) will compare all required testing in the contract to the commercial lab capability. If the testing facility is new and/or unknown to the DLA-PTC, a lab certification survey (DLA Form 6005, see section 5.1) will be provided for submission.

If the DLA-PTC has a lab survey on file that is less than 3 years old, that survey will be used for the initial evaluation. The DLA-PTC may ask for additional information or clarifications. If the laboratory survey on file is over 3 years old, a new form will be sent out for the testing facility to fill out. During the course of a contract, the laboratory may be asked to fill out another lab survey when the original survey becomes older than 3 years.

Note: The Qualified Laboratories List (QLL) previously maintained by DPSC has been canceled. No testing facility should refer to their previously issued QLL number.

1.6.2.1. Approval. If the testing facility and its named subcontractors meet the capability of the required testing, the DLA-PTC will notify the DLA Troop Support Product Specialist. Once approved by contracting, the testing facility becomes the Place of Performance and is placed in the contract.

1.6.2.2. Disapproval. If a testing facility does not meet the testing capability as per the specifications, the prime contractor is asked to submit another laboratory, and the process starts anew.

1.7. Government Furnished Material. Government Furnished Material (GFM) is material purchased and owned by the Government and is provided by the Government to a contractor for use in the performance of a contract. The contractor who has received the GFM from the Government is not required to test the GFM. The contractor is however required to notify the Government if they suspect or have determined that the GFM provided is deficient.

See paragraph 3.3.3 Defective Government Furnished Material for more information.

1.8. Government Furnished Equipment. Government Furnished Equipment (GFE) is equipment purchased and owned by the Government and is provided by the Government to a contractor for use in the performance of a contract.

1.9. Government Furnished Property. Government Furnished Property (GFP) is property purchased and owned by the Government and is provided by the Government to a contractor for use in the performance of a contract.

1.10. Toxicity Requirements. The contractor is responsible and must assure that all components are made from non-toxic materials. The Government reserves the right to verify that components are non-toxic in accordance with the following:

a. Title 40 Code of Federal regulations, current Edition and applicable sections.

b. As an alternative to animal and human testing, the contractor may provide information which certifies that components are composed of chemicals and/or materials which have been safely used commercially were prolonged skin contact has occurred.

2. INSPECTION REQUIREMENTS

2.1. Lot Formation. A Government Inspection Lot is a grouping of completed items or material from one continuous production run. The lot shall be of a set quantity from which the required test samples shall be randomly selected by a Government Quality Assurance Specialist (DCMA QAS), or Supplier’s Source Sampling Representative, as applicable. The contractor will consolidate to the maximum extent possible separate component shipments of the same production lot to preclude multiple sampling and testing of the same lot by the contractor or Government laboratories. Prime Contractors are required to maintain applicable records for each lot of their own production and to be able to produce records representing the treatment process for each lot of their subcontractors. Complete traceability shall be maintained for two years following delivery of the final lot of supplies. See ANSI Z1.4 for more information on lot formation.

2.1.1. Fabric Lot. Government lots shall be homogeneous production runs of material consisting of the same print and type of fabric, manufactured under the same conditions, from which the required testing samples are to be randomly selected. The original lot size and sample size shall be indicated on the test report and DD Form 1222 (see sections 5.2 and 5.3). Partial (incremental) shipments are permitted by the supplier after the lot has been sampled, but the test report shall not be adjusted to reflect partial shipments.

2.1.1.1. Physical Testing Sampling Plan. If not otherwise specified in the contract or specification, sampling for finished cloth testing shall be performed in accordance with the table below. Unless otherwise specified in the contract or specification, the sample unit shall be 5 continuous yards full width of the finished cloth per roll of cloth.

Lot size (yards) Sample Size (sample units)

800 or less 2

801 up to and including 22,000 3

22,001 and over 5

2.1.2. Component Lot. Government lots shall be homogenous production runs from which the required testing samples are randomly selected. The original lot size and sample size shall be indicated on the test report and DD Form 1222. Partial (incremental) shipments are permitted by the supplier after the lot has been sampled, but the test report shall not be adjusted to reflect partial shipments.

2.1.3. Manufacturing End Item Lot. Manufacturing Lots shall be comprised of end items possessing the same print, type of fabric, and style assembled into an identifiable stationary lot from which samples are randomly selected by the Government

Quality Assurance Specialist (DCMA QAS) in accordance with contract requirements for the purpose of Government inspection and acceptance. For end item testing, all tests shall be based on a definitive lot amount, and the test results and report shall apply solely to this amount. The lot formed for end item testing will correspond in quantity to the lot formed for end item examination and acceptance under DD Form 250 (see section 5.4). For end item testing of metallic heraldic items and embroidered insignia, the procedures for Component Lot, above, are to be followed.

2.1.3.1. Treated End Item Lot. A “Treated Lot” size may differ from the “Manufacturing Lot” size. Test results and full traceability must be maintained in association with each lot. Treated Lots shall be a completed production run comprised of a fixed quantity of end items possessing the same print, type of fabric, and style treated under the same conditions at the same time.

Samples for all Government Source Sampling Testing or inspection shall be pulled by the Government QAS from the completed Manufacturing Lot (or a partial quantity of the completed Manufacturing Lot, as described below) which has been assembled for final presentation to the Government.

2.1.3.2. Combining Manufacturing Lots in Treated Lot. Multiple completed Manufacturing Lots may be combined into a single Treated Lot as long as the garments being treated have the same print, type of fabric and garment style. Each Manufacturing Lot shall be independently counted for Government Source Sampling Testing purposes.

2.1.3.3. Multiple Treated Lots from a Manufacturing Lot. A single Manufacturing Lot may be treated in different Treated Lots. While the splitting of Manufacturing Lots should be minimized as much as possible, when a single Manufacturing Lot is too large to be treated as one Treated Lot, it may be treated in more than one Treated Lot. In this event, each Treated Lot is sampled individually for Government Source Sampling Testing purposes.

2.2. Lot Numbering. The contactor prior to presentation of each lot of finished items for Government acceptance, shall stamp legibly with indelible ink the Government lot number on each item and outer container in the lot except as provided hereafter, for specific items. For items within FSCs 8345 and 8455 Government lot numbers shall only be stamped on the intermediate and exterior packs. Discovery of illegible, incorrect, altered or missing lot numbers may result in rejection of the lot. The acceptance criteria for both contactor end item examination and Government examination on lot numbering errors shall be as follows:

Sample Size Illegible/Incorrect/Altered/Missing Acceptance Numbers

32 or less 0 0

33 - 50 0 1

51 - 80 1 2

81 - 125 2 3

126 - 200 3 5

201 - 315 5 7

316 - 500 7 10

501 - 800 10 14

801 - 1250 14 21

The marking will be designed to prohibit alteration or over stamping without visual evidence of this change. The following marking is acceptable:

01 -6- (8) 4M

A single digit by itself or a single vertical line is unacceptable since this can be easily changed. The lot number on an item/container will not be altered without knowledge and approval of the procurement activity. Should the entire contract quantity be presented for acceptance in a single lot, this lot numbering requirement is not applicable.

2.2.1. Serialization. When required, serialization of items within an End Item Lot shall enable Traceability to the raw materials used to produce the end item. The contractor is required to maintain records and the government reserves the right to request this information at any time. Individual serial numbers shall be assigned by the manufacturer. Serialization shall be by a block of consecutive numbers to cover the entire acquisition document quantity.

2.2.2. Traceability. The contractor shall maintain Traceability Records for all end items and component parts used to manufacture the End Item Product. For component parts purchased separately from the End Item Product, all Component Parts Lot Identification shall be traceable via the Component Part Lot Number. Component Part Lot Information shall enable Traceability to the raw materials used in the component part and/or the End Item Product. Traceability information shall also enable the manufacturer to determine the date of manufacture for the End Item Product and component parts. Each End Item Lot shall consist of one size, type, design, and color item. Further constraints to the number of Component Lots used within an End Item Lot may apply; refer to the contract for additional information.

2.3. Lot Integrity. The prime contractor will require the textile fabric supplier to present to the Supplier’s Source Sampling Representative the complete lot for shipment, a set of tally sheets by shipment listing case numbers, roll numbers and yardage of each roll, and a swatch (header) from each roll, with roll and case numbers identified on each swatch. The Supplier’s Source Sampling Representative will verify the integrity of the headers and roll numbers with the tally sheets by comparing the shade of the test samples selected for verification to the corresponding header. The QAS at the prime contractor’s facility will verify the integrity of the Component Lots by matching shipping documents with tally sheets and by comparing the shade of at least 1% of rolls received with swatches received from Set B (see section 3.2.1.1 for more information) submitted by the Supplier’s Source Sampling Representative. Samples of a questionable match will be sent to the DLA Product Test Center with DD Form 1222 Marked “Evaluated for Lot Integrity.”

2.4. Presentation of Lots. Whenever the contractor presents an examination record to the Government Quality Assurance Specialist (DCMA QAS), the lot of items represented by the examination record shall be assembled into an identifiable, stationary lot so that the QAS may draw samples to verify the contractor’s examination results. The QAS also verifies that vendor sent notice of lot presentation if required. If the appropriate lot presentation notice was not sent, sampling may be delayed. Samples shall be selected, stamped, and signed off by the source QAS, refer to 5.7 to requirements for QAS stamps for Clothing and Textile items.

2.4.1. Quality Assurance. Contractors are responsible for the quality of the items submitted to the government for inspection. Government Production Lot Inspection shall not replace a contractor’s own testing or quality assurance requirements.

2.4.2. Side-by-Side Sampling. Side-by-side sampling is not automatic. It is only required if directed by the DLA-PTC or if officially notified (via QALI, modification or as annotated on DLA Form 6004 (see section 5.5)) by the DLA Troop Support Product Specialist. When side-by-side sampling is applicable, the QAS will draw “side-by-side” samples and forward them to the DLA-PTC for testing along with their DD Form 1222 documentation.

2.4.3. ANSI ACQ Z1.4 (Switching Rules). Unless otherwise cited in the contract, production lot sampling and testing shall follow requirements stated within ANSI ACQ Z1.4. Alternative Release Procedures are prohibited unless prior approval is granted by

DLA.

3. QUALITY TESTING REQUIREMENTS

3.1. Certified Test Reports. Test reports shall be signed and certified by the testing facility, accompanied with a DD Form 1222 and emailed to the Government for evaluation to the following address: paactlab@dla.mil.

The test report presented to the Government shall be not older than ninety (90) calendar days. A separate report shall be provided from each test facility when a single lot of material, components, or end items is tested by more than one test facility for different characteristics.

These separate reports may be combined and submitted with a single DD Form 1222. All certifications made under the contract are covered by a statutory provision regarding false statements, U.S.C. Title 18, Section 1001, which provides a fine of not more than $10,000 or imprisonment for not more than five (5) years, or both. See Section 5.6, End Item Test Report Example.

3.1.1. Completion of DD Form 1222. Each certified test report shall be accompanied by a DD Form 1222. The DD Form 1222 must be signed, stamped and dated by the QAS in box 15 (see DCMA policy memorandum in section 5.7).

mailto:paactlab@dla.mil

The DD Form 1222 Section A is required to be filled out in its entirety. For routine shade or physical testing of fabric lots, Government sampling is not required. The DD Form 1222 for routine shade or physical testing of fabric lots shall be signed and dated by the Supplier’s Source Sampling representative in Box 15. Incomplete DD Form 1222s will be returned to the contractor. Section B of the DD Form 1222 will be reserved for use by the DLA Product Test Center. See Section 5, DD Form 1222 Example. Use the newest available published version of DD Form 1222.

3.1.1.1. Multiple Contractors. When multiple contractors are cited to receive a portion of the quantity represented in block number 11 of DD Form 1222, they shall be noted in either box 3 or box 22. The number of contracts listed on a DD Form 1222 is limited to six.

3.1.2. Test Report Data. The test report shall specify all test results and include the date testing was completed. The lot size, sample size, Government lot number, specification, and roll number should be noted. Each test characteristic (including units) and analytical results are to be reported, including ALL determinations made on each sample unit. In addition, the test report should include the result of each sample unit and the lot average, if there is a lot average requirement. The contract requirement for each test characteristic is to be included. Pass or Fail, if applicable, shall also be indicated for each test performed and represented on test report. Failing results shall be noted by an asterisk. Test reports shall include a signed certification by the laboratory and the supplier that only those samples drawn by the Government QAS or Supplier’s Source Sampling Representative, as applicable, were tested and the test report represents a sample size consistent with applicable specification requirements.

Where contractors have computerized their material certification for components and end items, the test reports shall have an actual or electronic signature, or have attached to the test reports a letter signed by the corporate/company officer attesting that the contractor is using a computerized system, the typed name on the report is an authorized employee, and the contractor is liable for the information it contains.

3.1.3. Certificate of Compliance (CoC) Submission. When the total cost of a component required for the entire contract quantity does not exceed $100,000, the contractor may provide to the Government a Certificate of Compliance for this component, unless otherwise specified. All Certificates provided by the contractor shall be supported by test reports to ascertain their validity. Contractors are required to provide these test reports to the Government when requested by the Government. The Government reserves the right to check and test items provided with a Certificate of Compliance to determine the validity of the certification. See section 5.9: CoC Example.

3.2. Government Acceptance Testing. Unless otherwise stated in the contract, testing performed at the DLA PTC for acceptance purposes will be completed in forty five (45) calendar days. The contract delivery requirements are based on the assumption that DLA Troop Support and the DLA PTC will require a total of 45 calendar days from the date of the receipt of samples at the Government laboratory to the date the completed test results are mailed to the contractor. If this time frame is exceeded, the contract delivery schedule will be extended by the number of additional days needed to complete the testing, provided the contractor can establish that the delay in its delivery was caused by the Government exceeding the prescribed time. The foregoing provision for the extension of delivery schedules is exclusive and the Government shall not be liable to suit for breach of contract by reason of any delay of the Government in providing test results.

3.2.1. Shade Evaluation. Shade Evaluation is Acceptance Testing; each lot must be submitted for evaluation. Lots shall not be shipped until shade is approved by Government. The prime contractor will require the fabric or component supplier to present to the Supplier’s Source Sampling Representative the complete lot prepared for shipment, a set of tally sheets by shipment listing case numbers, roll numbers, and yardage of each roll and a shade swatch (header) from each roll with roll and case numbers identified on each swatch. The following sampling procedure will be followed unless otherwise specified.

3.2.1.1. (a) Sampling. Sampling will be specified in the Shade Evaluation Clause of the contract as either 100% or through a statistical sampling procedure as specified for that component in the contract. Unless otherwise specified, the table below will be used to determine quantity for submission.

Caution: In one contract there may be multiple components requiring shade sampling and each component may require a different sampling method.

Lot Size No. of Rolls to be sampled

1 to 8 rolls Each roll

9 to 25 rolls 8 rolls

26 to 90 rolls 20 rolls

91 to 160 rolls 32 rolls

Over 160 rolls 1/5 of total rolls

Cutting Swatches. The Supplier’s Source Sampling Representative is required to physically sample the material in one of the below manners, as defined by the contract. The result of the material sampling will be two sets of samples: Set A and Set B. Set A shall be sent to DLA Product Test Center for evaluation. Set B shall be cut in half, one set sent to the prime QAS for lot integrity, the other set shall be retained by the component supplier.

Single color rolls - 4"x24". Supplier’s Source Sampling Representative cuts this sample in half to have A and B sets, both sets shall be 4"x12". The 12" should be in the Filling Direction or cross- machine direction.

Multi-color Camouflage including OCP and OEFCP – full width x 2 yd.

Supplier’s Source Sampling Representative cuts this sample in half to have A and B sets, both sets shall be full width by 1 yard. The 1 yd. should be in the warp direction.

3.2.1.1. (b) Sampling. Size/units for all components items such as webbings, binding tapes, and fastener tapes that are to be forwarded for shade evaluation, will be determined by Annex A.

3.2.1.2. Submission. Each lot of a component required by the contract to have shade evaluation shall be submitted to the DLA Product Test Center— Analytical for evaluation. Samples shall be selected and signed off by the Supplier’s Source Sampling Representative. Samples, accompanied with a DD Form 1222, Section A completed in its entirety, shall be forwarded to the Government for evaluation to the following address. Incomplete DD Form 1222s will be returned and the lot not evaluated until the corrected form is received. See Section 5.3, DD Form 1222 Example for Shade.

DLA Product Test Center—Analytical

700 Robbins Avenue Bldg. 5D

Philadelphia, PA 19111

3.2.1.3. Shipment of Shade Evaluation Lots. Components requiring shade evaluation shall not be shipped to the prime contractor until shade is approved by the Government. Approval is through the Government issuance of the DD Form 1222 with passing test results. Approval may also be granted through the Request for Waiver process and a DLA Form 6004 will be issued by the Government designating approval of waiver request, if request is denied, components shall not be shipped to prime contractor.

3.2.1.4. No Shade Clause in Contract.

1. When no shade clause is cited in the contract, the prime contractor shall contact the Contracting Officer (KO) to ensure there are no requirements for shade testing.

2. When no shade clause is cited in the contract, the Supplier’s Source Sampling Representative will perform in-house shade evaluation according to the requirements cited in the specification.

3.2.2. Near Infrared (nIR). When cited in the contract that Near Infrared Testing is Acceptance Testing; sampling shall be through a statistical sampling procedure cited in the contract. Samples shall be selected and signed off by the Supplier’s Source Sampling Representative. Cut a 36" x full width sample. Supplier’s Source Sampling Representative cuts this in half to have an A and a B set. Both sets are now 18" x full width. Set A shall be sent to the DLA PTC for evaluation. Samples, accompanied with a DD Form 1222, Section A completed in its entirety, shall be forwarded to the Government for evaluation to the following address simultaneously but separately from any shade submissions. Incomplete DD Form 1222s will be returned and the lot not evaluated until the corrected form is received.

DLA Product Test Center—Analytical

700 Robbins Avenue Bldg. 5D

Philadelphia, PA 19111

Shipment of nIR Acceptance Lots shall follow the procedure outlined for shade in section 3.2.1.3.

3.2.3. Production Lot Testing. When applicable, both the Government and the contractor’s laboratories will test every lot. The Government’s test results will be used for acceptance/rejection purposes. In order to avoid shipping delays, it is recommended that the government and contractor’s testing occur simultaneously. Sampling will be specified in the contract as either 100% or through a statistical sampling procedure as specified for that component in the contract. Samples shall be selected, stamped, and signed off by the source QAS.

3.2.4. Verification Testing. When applicable, both the government and contractor’s laboratories will perform the same tests to correlate results. The Government’s test results will be used for acceptance/rejection purposes. In order to avoid shipping delays, it is recommended that the government and contractor’s testing occur simultaneously. Sampling will be specified in the contract as either 100% or through a statistical sampling procedure as specified for that component in the contract. Samples shall be selected, stamped, and signed off by the source QAS.

3.3. Government Contractor Testing. Testing required in a contract but not identified as being Government Acceptance Testing shall be performed as stated in the contract and in compliance with the below.

3.3.1. Notification. The vendor shall notify the DLA-PTC representative via email between fourteen (14) calendar days and thirty (30) calendar days from when lots are to be presented to the QAS or Supplier’s Source Sampling Representative. This allows arrangements to be made if the lab specialist requests to witness testing at the place of performance. The DLA-PTC will reply in writing by the date of lot presentation, whether witnessing, or side-by-samples, are requested. If no reply is received by the date of presentation to the QAS or Supplier’s Source Sampling Representative, the contractor may proceed.

Notifications should include:

Commercial lab contact information

Government lot #

Contract

Product

Specification

Date of lot presentation to the QAS

3.3.2. Contractor Furnished Material (CFM). DLA Troop Support Clothing and Textile contracts require source sampling of CFM at finishing plants. The following provisions apply to sample selection and lot acceptance.

(a) The Samples shall be randomly selected by the Supplier’s Source Sampling Representative.

(b) Upon presentation of a lot, the Supplier’s Source Sampling Representative will draw samples and forward the samples to the contractor’s laboratory specified in the contract for testing.

(c) Shipment of Component Lots from the source to the prime contractor need not be deferred except for Government Acceptance Testing (i.e., shade evaluation). Commencement of production prior to receipt of a passing test report from the contractor’s authorized laboratory is solely at the contractor’s risk.

(d) The contactor will provide copies of Certificates of compliance to the QAS.

(e) The contractor is required to ensure that a complete test report for all lots is furnished to the source’s QAS and the appropriate DLA-PTC representative.

3.3.3. Defective Government Furnished Material. The contractor who has received the GFM from the Government is not required to test the GFM. The contractor is however required to notify the Government if they suspect or have determined that the GFM provided is deficient. The Contractor shall submit DLA Form 506 Certificate of Deficient Government Furnished Material (see section 5.10) and is required to notify their contracting officer. The Government will investigate the contractor’s claim of deficient GFM and advise contractor what actions will be taken if necessary.

3.3.4. Correlation Testing. When applicable both the Government and the contractor’s laboratories will perform the same testing to correlate results. The contractor’s test results will be used for acceptance/rejection purposes. If results for correlation testing indicate significant variation between the government and contractor, on site survey, and/or additional testing shall be performed to assure the validity of test results.

3.4. Non-Conforming Material. In the event of non-conforming material, the vendor may be required to submit a Failure Analysis and Corrective Action Plan (FACAP) to address the non-conformance. The FACAP shall include at minimum: a detailed, specific description of the problem, how many items are effected, when, where, and how the non-conformance was discovered, root cause analysis of the failure that explains why the failure happened, how the failure will be corrected and prevented in the future. Based on the non-conformance, the vendor may elect to submit a Request for Variance. Furthermore, Material Review Board (MRB) authority may be withheld by the Government for certain items and contracts. MRB authority is defined as disposition of nonconforming material whose non-conformance affects adherence to internal specifications or end item requirements. Non-conforming material can be any item, part, supplies, or product containing one or more non-conformities.

3.4.1. Waiver Process. All Requests for Variances (RFVs) shall be directed toward the Contracting Officer after coordinating it with the DCMA QAS. RFVs shall be submitted completing the DD Form 1694 (see section 5.11) unless otherwise specified in the contract or by the KO. The Government reserves the right to deny any Request for Variance. Based on the item and/or the classification of defect that the RFV is submitted against, further review by the responsible Engineering Support Activity may be required. Official RFV response will be sent to the vendor via official letter signed by the KO.

3.4.1.1. Resubmitted Lots. Notwithstanding any contract provisions, each resubmitted lot previously rejected by either the contractor or the Government shall be re-examined by the contractor using tightened inspection criteria for all the characteristics listed for that category of defects (i.e., visual, dimensional, preparation for delivery) that caused the lot to be rejected. In addition to the above requirements, the Government also requires that the next original lot (for the same item) be examined using tightened inspection criteria, unless otherwise prescribed. All supplies rejected by the Government shall be screened, corrected and re-examined by the contractor using tightened inspection and resubmitted to the Government.

3.4.1.2. Tightened Inspection. When normal inspection is in effect, tightened inspection shall be instituted when 2 out of 5 or fewer consecutive lots or batches have been non-acceptable on the original inspection (i.e., resubmitted lots are not taken into account in this procedure) and also as directed by the government.

3.4.2. Corrective Action Plan (CAP) Process. After a non-conformance is detected, the contractor may be required to submit a CAP prior to the authorization of further testing or resubmission of items for presentation. A complete CAP shall consist of the following 6 factors:

(a) Problem description. The problem description shall be a specific description of the problem including how many items were initially found to contain the problem, along with how, when and where the problem was discovered.

Identification information of the items effected should include at a minimum:

quantity per contract number(s), size (if applicable), NSN(s), item nomenclature, lot(s), date and location of manufacture, design code (if applicable), and serial number (if applicable).

(b) Containment actions/short term corrections. The containment actions should specify the quantity of suspect product at the vendor’s facility, the method of quarantine, and how quarantined items are identified. For items that have been evaluated and determined to not contain the non-conformance, the method of certification against the problem and how these items are identified should also be included. If there is suspect product in transit or already delivered to the customer or depot, these items must also be identified.

(c) Root cause analysis. Once containment/short term actions have been completed, the root cause analysis shall be performed and include an explanation of why the failure happened and why it was not detected. To verify the true root cause has been identified, explain in detail what actions were taken to assure that no other root cause could be responsible for the problem.

(d) Corrective actions/verifications of corrective actions. Once the true root cause or causes has been identified, the corrective actions shall be established to remedy the problem. Each action item should be listed individually and include the date of implementation and department/person responsible for implementing the action. Provide detail of how each action taken assisted in eliminating the problem. The action items shall address both the occurrence of the problem and also the non- detection of the problem.

(e) Standardization and control. After corrective actions have been implemented and proven effective, vendor documentation (i.e., work instructions, process control plans, visual aids, preventative maintenance plans, operating procedures, etc.,) shall also be updated to include the corrective actions.

(f) Verification of corrective actions. To verify the corrective actions after standardization and control has been addressed, describe the methods used to verify the actions taken are effective and will remain effective. Include as much data as possible to support the effectiveness of the actions.

Once the CAP information is available, it shall be submitted to the cognizant DCMA QAS for review prior to submittal to the Contracting Officer. The CAP may be reviewed by DLA and the applicable Engineering Service Activity. Once the review has been completed, the KO will provide an official letter summarizing the disposition regarding the initial problem, approval/disapproval of the CAP, and the path forward.

4. FINAL EXAMINATION

4.1. Contractor’s Obligation for Examination. The contractor is required (unless otherwise specified) to perform all examinations set forth in the contract. The contractor will certify the results of these examinations and have certified records of these examinations available for review by the Government. The contractor will perform single sampling according to ANSI-ASQC Z1.4, unless the contract cites otherwise. Where the end item is being manufactured in more than one facility, the contractor will examine each lot produced at each facility and ensure that each lot retains its identity as a separate inspection lot.

4.2. Presentation of End Item Lots. Whenever the contractor presents an examination record for the end items to the Government Quality Assurance Specialist (DCMA QAS), the lot of items represented by the examination record shall be assembled into an identifiable, stationary lot so that the QAS may draw samples to verify the contractor’s examination results.

4.3. Product Acceptance and Release. The DCMA QAS shall randomly sample items from lots per contract requirements after the complete production lot is available. Unless written approval is granted by the Contracting Officer, contractors are prohibited from selecting samples for government testing. The DCMA QAS shall verify that the contractor has all test reports and Certificates of Compliance available for review at any time during the contract.

DCMA QAS shall perform examinations as specified in contract and notify DLA Troop Support of any discrepancies found. If discrepancies are found during this examination, DCMA QAS shall issue a Corrective Action Report (CAR) and forwarded a copy to the Contracting Officer. DCMA QAS shall maintain their examination records and make them available to DLA upon request.

5. FORMS

5.1. DLA Form 6005 Laboratory Testing Capabilities Survey

5.2. DD Form 1222 for Source Sampling

5.3. DD Form 1222 for Shade

5.4. DD Form 250 Material Inspection and Receiving Report

5.5. DLA Form 6004 Clothing & Textile Laboratory Test Report and Instructions

5.6. Lab Report Sample

5.7. Letter of Exception for DCMA Stamps

5.8. Certificate of Compliance

5.9. DLA Form 506 Certificate of Deficient Government Furnished Material

5.10. DD Form 1694 Waiver Request

5.11. DD Form 1222 Correlation Testing

5.12. Instructions for Submitting a DD Form 1222

5.1. DLA Form 6005 Laboratory Testing Capabilities Survey

DLA PRODUCT TEST CENTER

700 ROBBINS ST., BLDG 5D

PHILADELPHIA, PA 19111

TWILL INDUSTRIES

JANE JONES

GOVERNMENT WARFIGHTER INCORPORATED

SPE1C1-10-D-0456

TWILL INDUSTRIES

Blouse, Marine Corps Desert Uniform Source Sampling 20170512

Cloth, Nylon/Cotton 3 - 5 yd pieces 3,124 yd MIL-PRF-MCCUU E, Class I, Type II

Jane Jones

By signing in box 15, I certify that the samples referenced above were randomly selected and represent the lot identified above.

Shade: MARPAT Desert Roll #3848 Sample numbers: 769322, 769245, 769252 warfighter@gwi.com; jjones@twillinds.com

5.2. DD Form 1222 for Source Sampling

SAMPLE

PHILADELPHIA, PA 19111

TWILL INDUSTRIES

JANE JONES

GOVERNMENT WARFIGHTER INCORPORATED

SPE1C1-10-D-0456

TWILL INDUSTRIES

Blouse, Marine Corps Desert Uniform Shade Evaluation 20170512

Cloth, Nylon/Cotton 7 swatches 3,124 yd MIL-PRF-MCCUU E, Class I, Type II

Jane Jones

By signing in box 15, I certify that the samples referenced above were randomly selected and represent the lot identified above.

Shade: MARPAT Desert Roll #3848 Sample numbers: 769322, 769245, 769252, 769258, 769260, 769263, 769282 warfighter@gwi.com; jjones@twillinds.com

5.3. DD Form 1222 for Shade

5.4. DD Form 250 Material Inspection and Receiving Report

5.5. DLA Form 6004 Clothing & Textile Laboratory Test Report and Instructions

Stark Industries 47 Ishamel Ave, New York, NY 07319

Tel: (402)-555-1660 Fax: (402)-555-1611

Specification: GL/PD 13-04A/13-08A & 13-05A/13-09A, Dtd. 19-March-2014 Product: Basic Material, Jacket/Pants (Unisex & Female) Army Physical Fitness Uniform Customer: Various Lot: 3 Item: MP90700S Shade: Black 557 Yardage: 12,368 Testing Completed: July 25, 2014 Contract No. SPM1C1-10-D-F010, SPM1C1-12-D-F512

Test: Fed. Std. 191A Roll #1 Roll #1 Roll #1 Unless Noted Otherwise 631613 631799 631948

Weight, oz./sq.yd. 3.5 3.5 3.5 p.p 3.4.1, ASTM D 3776 Option C 3.5 3.4 3.5

3.5 (+/- 0.3) 3.5 3.4 3.4

3.5 3.5 3.5

3.5 3.4 3.5

5 Readings w/average 3.5 3.4 3.5

Yarns per inch Warp Warp Warp

ASTM D 3775 160 159 159

Warp 157 minimum 159 159 159

159 159 160 159 159 159 159 159 159

5 Readings w/average 159 159 159

Yarns per inch Fill Fill Fill

ASTM D 3775 74 72 74

Fill 66 minimum 74 72 74

74 72 74 74 72 74 73 73 74

5 Readings w/average 74 72 74

5.6. Lab Report Sample

Stark Industries 47 Ishamel Ave, New York, NY 07319

Tel: (402)-555-1660 Fax: (402)-555-1611

Specification: GL/PD 13-04A/13-08A & 13-05A/13-09A, Dtd. 19-March-2014 Product: Basic Material, Jacket/Pants (Unisex & Female) Army Physical Fitness Uniform Customer: Various Lot: 3 Item: MP90700S Shade: Black 557 Yardage: 12,368 Testing Completed: July 25, 2014 Contract No. SPM1C1-10-D-F010, SPM1C1-12-D-F512

I certify that the samples referenced above were randomly selected and represent the lot of components identified above. I further certify that the components tendered are all part of the lot of components referenced herein.

The above sales order was evaluated for shade using AATCC evaluation procedure 9 option A and was determned to be an acceptable match when compared to the standard.

Signed VP Samuel Date: July 25, 2014 VP Samuel Vice President of Manufacturing Stark Industries

I certify that the above lot was tested under my supervision in accordance with the specification test requirements and the reported test results are true, valid and applicable to the s amples tested.

The component lot referenced above was found to be passing, reliable, and meeting the requirements of the above specification.