Attachment 0025 - MET Trailer Failure Definition Scoring Critieria.pdf

CUI

11 May 2021

Failure Definition and Scoring Criteria (FDSC) for the Medium Equipment Trailer (MET)

U.S. Army Futures Command Futures and Concepts Center

Futures Integration Directorate RAM Engineering Division

950 Jefferson Avenue Fort Eustis, VA 23604

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense (DoD) and U.S.

DoD contractors only to protect technical or operational data or information from automatic dissemination under the International Exchange Program or by other means, 6 May 2021. Refer other requests for this document to: U.S. Army Futures Command, Futures and Concepts Center, Futures Integration Directorate, RAM Engineering Division, 950 Jefferson Avenue, Fort Eustis, VA 23604.

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Failure Definition and Scoring Criteria (FDSC) for the Medium Equipment Trailer (MET)

Harishkumar O. Doshi

U.S. Army Futures Command

Futures Integration Directorate RAM Engineering Division

950 Jefferson Avenue Fort Eustis, VA 23604

DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense (DoD) and U.S.

DoD contractors only to protect technical or operational data or information from automatic dissemination under the International Exchange Program or by other means, 6 May 2021. Refer other requests for this document to: U.S. Army Futures Command, Futures and Concepts Center, Futures Integration Directorate, RAM Engineering Division, 950 Jefferson Avenue, Fort Eustis, VA 23604.

ii iii

Foreword

PURPOSE

The Failure Definition and Scoring Criteria (FDSC) serves as the user's primary tool for scoring and evaluating systems during developmental and operational testing events. The FDSC drives system design, development, and testing and evaluation. The following FDSC defines what the user considers degraded and unacceptable performance of the Medium Equipment Trailer (MET) and outlines the process for categorizing all failure events that occur during system testing. The FDSC will be the basis for the evaluation of the reliability requirement. There is no intent to address every situation that will arise during reliability testing. When discovering limitations to the FDSC, the capability developer RAM engineer in coordination with the materiel developer and independent evaluator will update and add appropriate information to the FDSC as required.

SYSTEM DESCRIPTION

The MET is a trailer used to transport intermediate weight combat vehicles up to 60 tons (e.g., Bradley Fighting Vehicle, Armored Multi-Purpose Vehicles, Paladin, and Field Artillery Ammunition Support Vehicles) and is capable of clearing 4-meter underpasses using the M1300 Tractor as the prime mover. It may include an Auxiliary Power Unit (APU) to power semi-trailer hydraulics and deck operations if the vendor provides those capabilities.

POINT OF CONTACT

Mr. Harishkumar Doshi, Futures and Concepts Center, RAM Engineering Division, Fort Lee Field Office, Commercial 804-734-1521, email harishkumar.o.doshi.civ@mail.mil.

CERTIFICATION

Date: 11 May 2021 Jeffrey L. Higgins Chief, Central RAM Engineering Branch RAM Engineering Division Futures Integration Directorate

Army Futures Command iv v

Table of Contents

Foreword ....................................................................................................................................... iii Purpose ....................................................................................................................................... iii System Description .................................................................................................................... iii Point of Contact .......................................................................................................................... iii Certification ................................................................................................................................ iii

Table of Contents ...........................................................................................................................v List of Figures ..............................................................................................................................v List of Tables ................................................................................................................................v

System Description, Essential Functions, and Failure Defintion System Description Essential Functions Failure Definition

Scoring Criteria Test Data Collection Guidance

Appendix A – References ......................................................................................................... A-1 Appendix B – Glossary ..............................................................................................................B-1

List of Figures

Figure 1 – Scoring Process Flow Chart

Figure 2 – Scoring Process Flow Chart Steps

List of Tables

Table 1 – Leak Classification vi

System Description, Essential Functions, and Failure Definition

SYSTEM DESCRIPTION

The MET is a trailer used to transport intermediate weight combat vehicles up to 60 tons (e.g., Bradley Fighting Vehicle, Armored Multi-Purpose Vehicles, Paladin, and Field Artillery Ammunition Support Vehicles) and is capable of clearing 4-meter underpasses using the M1300 Tractor as the prime mover. It may include an Auxiliary Power Unit (APU) to power semi-trailer hydraulics and deck operations if the vendor provides those capabilities.

ESSENTIAL FUNCTIONS

Essential functions are the minimum operational tasks that the MET must be capable of performing to successfully complete its mission. The loss of any essential function, regardless of when it occurs is an essential function failure (EFF).

Move. Whether loaded or unloaded, the MET must be capable of being safely towed by the M1300 tractor or similar within tactical convoys over primary and secondary roads as described in the MET Operational Mode Summary/Mission Profile (OMS/MP).

Load/Unload. The MET must allow for the loading or unloading of designated vehicles of appropriate size and weight within its payload limits.

Secure Load. The MET must allow for tying /securing of designated payloads within its payload limits for highway transport.

Transport Load. The MET must be capable of safely transporting designated payloads within its payload limits while being towed by the M1300.

FAILURE DEFINITION

Formal Failure Definition.

Essential Function Failure (EFF) An Essential Function Failure (EFF) is any event that results in the loss of or operationally unacceptable degradation in one or more of the essential functions or any Class II or III fuel leak.

(See Table 1).

System Abort (SA) A System Abort is an event that results in the loss or degradation of an essential function(s) that renders the system unable to enter service or causes immediate removal from service (a SA may result in a “Not Mission Capable” status under wartime conditions, or reduces its utility to the point that it is deemed ineffective/unsafe in its role on the battlefield). By definition SA is also an

EFF. System abort also includes any event that creates a Category I (catastrophic) or II (critical) hazard as defined in MIL-STD-882.

Non-Essential Function Failure (NEFF) Events that result in loss of or degradation in non-essential functions or minor degradation in essential functions, which do not reach the levels to qualify as an EFF. For example, any malfunction or fault the operator can defer until after an operation is not an EFF. NEFF events include Class I fuel leaks and Class I-II-III coolant, oil or any other fluid leaks that would not interrupt the MET’s abilities. (See table 1).

Dependent Event (DE). A reliability event that is a secondary malfunction caused by the failure of another item, which normally occurs simultaneously or nearly simultaneously with the causing event. Normally all related information is reported and scored on a single Test Incident Report (TIR); this category is used when related failures are reported on separate TIRs and it is appropriate to treat the incidents as a single failure. In some cases, it may be necessary to present engineering evidence to clearly link the DE to the causing event. The related incidents are scored as if one incident had occurred. The score of the first (primary) incident should reflect the combined effect of the primary and all secondary related failures (EFF, SA, etc.). The secondary incident(s) are scored as DEs and charged to the failure of the primary incident (using Primary Incident Chargeability). Thus, the system is charged a single failure event but all related maintenance time is counted.

Rapidly Recoverable Events (RRE) Minor events corrected by the operator/crew within 30 minutes will be scored as Rapidly Recoverable Events (RRE) if the repair procedure is identified in the operator’s manual and is performed using only on-board tools and repair or spare parts. More than 3 RRE during a mission will be scored on their own merit. The event would normally be scored at a higher level (SA or EFF); however, because the failure can be rectified rapidly as per definition it is scored as an RRE.

Table 1. Leak Classification Class I Seepage of fluid indicated by wetness or discoloration not great enough to form drops.

Class II

Leakage of fluid great enough to form drops but not enough to cause drops to fall from item being checked/inspected.

Class III Leakage of fluid great enough to cause drops to fall from item being checked/inspected.

Scoring Criteria

Scoring Criteria

The scoring criteria section describes the process for classifying all test incident reports (TIR) generated during a reliability test. The Reliability Scoring Conference (RSC) members use the scoring criteria to assign TIRs into proper categories, sub-categories, and chargeability. Figure 1 is a scoring flow chart depicting this process. TIR categories are: Reliability Event (i.e., failure), Non-Reliability Event (applicable to maintainability), or Other Test Event (not applicable to RAM). Appendix A – Glossary includes the scoring process flowchart definitions. Figure 2 describes the scoring process flowchart steps.

Non-Reliability Event Other Test EventReliability Event N N

Y

Determine Category

• EFF

• SA

• NEFF

• RRE

• DE

Determine Cause

• Preventive Maintenance Checks and Services

(PMCS)

• Scheduled Maintenance

• Routine Operating

Procedures (ROP)

• On-Condition

Maintenance

• Other (specify)

Determine Cause

• Pre-/Post-Test Checkout

• Equipment Modification

(Hardware or Software)

• Test Peculiar Event (TPE)

• Abuse or Misuse

• Unrelated Damage

• Non-RAM Oriented/

Informational

• Performance Limitation

• Other (specify)

Y Y

Test Incident Reported

Determine Cause

• Accident

• Support Equipment

• Indeterminate

• Tech Document/Manuals

• Primary Failure

• Hardware

• Software

• Operator (crew)

• Maintenance Personnel

• Training

• Other (specify)

Figure 1. Scoring Process Flow Chart.

Figure 2. Scoring Process Flowchart Steps.

1. Test Incident Report (TIR) Scoring. Select the appropriate category below and proceed as directed.

• Test Incident is a “Reliability Event.” Proceed to step 2.

• Test Incident is a “Non-Reliability Event.” Proceed to step 4.

• Test Incident is an “Other Test Event.” Proceed to step 5.

2. Reliability Event. Identify the reliability event as one of the following sub-categories and proceed to step 3. A reliability event can include post-test TIRs, with or without maintenance actions, if the failure occurred during record test.

• Essential Function Failure (EFF)

• System Abort (SA) (by definition also is an EFF)

• Non-Essential Function Failure (NEFF)

• Rapidly Recoverable Event (RRE)

• Dependent Event (DE)

3. Failure Chargeability. Identify a single root cause of the reliability failure from the following list and proceed to the next test incident.

• Accident

• Support Equipment

• Indeterminate

• Technical Documentation/Manuals

• Primary Failure

• Hardware (Government Furnished Equipment (GFE)/Contractor Furnished Equipment

(CFE))

• Software GFE/CFE

• Operator/Crew

• Maintenance Personnel

• Training

• Other (Specify)

4. Non-Reliability Event (Applicable to Maintainability). Select the sub-category from the list below and proceed to the next incident.

• Preventive Maintenance Checks and Services (PMCS)

• Scheduled Maintenance

• Routine Operating Procedure (crew-performed IAW manual)

• On Condition/Condition Based Maintenance

• Other (Specify)

5. Other Test Event (OTE) (Not applicable to RAM). Select the sub-category from the list below and proceed to the next test incident.

• Pre/Post-test Checkout

• Equipment Modification (Hardware or Software)

• Test Peculiar Event (TPE)

• Abuse or Misuse

• Unrelated Damage

• Non-RAM Oriented/Information (NRO)

• Performance Limitation (PL)

• Other (Specify)

Test Data Collection Guidance

This section includes any specific instructions to testers to facilitate accurate collection and recording of data relevant to RAM scoring. TIRs document all incidents where a system is non-operational, operates with degraded performance, or responds differently than expected. They should contain as much information as possible with regard to failures and, when possible, to the root cause of the failures. Below is a typical list of data and information to record within a TIR:

• Failure initiation date (date, time, location, malfunction indicators).

• System operation(s) attempted at time of failure.

• Operating hours, miles, cycles, or other measurement(s) used to quantify the age or life of the system/component at time of failure.

• Maintenance Actions performed.

• Maintenance level used.

• Maintenance man-hours.

• Maintenance clock-hours.

• Military Occupational Specialty (MOS) used.

• Spare or repair parts used.

• Petroleum, Oil, and Lubricant (POL) quantity used.

• Indication of Built-in-test/Built-in-test-equipment (BIT/BITE) false alarm.

• Indication of BIT/BITE successful detection.

• Indication of BIT/BITE successful isolation.

A-1

Appendix A – References

Army Regulation 702-19. Reliability, Availability, and Maintainability. Headquarters Department of the Army, Washington, DC. 12 February 2020.

Guide for Developing Reliability Failure Definition and Scoring Criteria (FDSC), 5th Edition.

US Army Futures Command, Fort Eustis, VA. 4 November 2020.

MIL-STD-882E. System Safety. Department of Defense, Washington, DC. 11 May 2012.

A-2

B-1

Appendix B – Glossary

Abuse or Misuse. Events in which official test participants (crewmembers or maintenance personnel) cause damage to the system either willfully or through gross negligence are subject to being classified as abuse (ultimately, a decision for the Scoring Conference members to make after considering the facts). This category also includes any incidents in which the tester directs the deliberate misuse of the system (e.g. a test excursion to exceed the performance limits of the system), whether called for by the test plan or not.

Accident. Failure Chargeability category for accident induced failure/damage not attributable to the design of the system or operator negligence.

Crew/Operator. Failure chargeability category that includes all incidents attributable to crew/ operator error.

Dependent Event (DE). A reliability event that is a secondary malfunction caused by the failure of another item, which normally occurs simultaneously or nearly simultaneously with the causing event. Normally all related information is reported and scored on a single Test Incident Report (TIR); this category is used when related failures are reported on separate TIRs and it is appropriate to treat the incidents as a single failure. In some cases, it may be necessary to present engineering evidence to clearly link the DE to the causing event. The related incidents are scored as if one incident had occurred. The score of the first (primary) incident should reflect the combined effect of the primary and all secondary related failures (EFF, SA, etc.). The secondary incident(s) are scored as DEs and charged to the failure of the primary incident (using Primary Incident Chargeability). Thus, the system is charged a single failure event but all related maintenance time is counted.

Essential Function Failure (EFF) An Essential Function Failure (EFF) is any event that results in the loss of or operationally unacceptable degradation in one or more of the essential functions or any Class II or III fuel leak.

Equipment (System) Modification (hardware or software). Installation of hardware kits, software modifications, or incorporation of redesigned components or software upgrades.

Hardware. Chargeability category that includes malfunctioning hardware as well as personnel related incidents that are attributable to the hardware's design. This category may be broken down further into hardware that is “Contractor Furnished Equipment (CFE)” and/or “Government Furnished Equipment (GFE)”.

Indeterminate. Chargeability category for incidents that do not have sufficient information/data to permit a determination of chargeability.

Maintainability. A measure of a system’s ease of maintenance.

B-2

Maintenance Personnel. This chargeability category includes all incidents attributable to maintenance personnel errors not due to hardware/software design/coding problems, poorly written manuals, human factors/ergonomic issues, or faulty embedded diagnostics.

Malfunction. Failure to properly perform a specified action or activity.

Non-Essential Function Failure (Non-EFF). Events that result in loss of or degradation in non-essential functions or minor degradation in essential functions, which do not reach the levels to qualify as an EFF. For example, any malfunction or fault the operator can defer until after an operation is not an EFF.

Non-RAM Oriented/Information. Category for Test Incident Reports (TIR) excluded from RAM computations. Examples include suggested improvements, reports on inadequate test procedure, unusable or unacceptable replacement parts discovered prior to or during installation, test schedule delays, suggested human factors improvements or recommended changes to the system support package not related to a specific test event.

Non-Reliability Event (Applicable to Maintainability). Event, which is not a reliability failure, but may have implications on system maintainability.

On-Condition/Condition Based Maintenance (CBM). Incident recording maintenance performed to replace a used or worn part/component that has met its life expectancy criteria (i.e., its durability or service life requirement). The part must still be functioning at the time of its replacement. The system technical documentation must have specific criteria to identify conditions for replacement. Examples of “on-condition” maintenance include replacement of tires due to normal wear (tread wear indicators showing/tread depth less than “wear-out” standards) or gun tube replacement based on the specified item meeting the necessary interval (e.g. rounds, hours, or miles), or durability requirements. It may be necessary to further record whether the item being replaced is Contractor Furnished Equipment (CFE) or Government Furnished Equipment (GFE), depending on the nature of the R&M requirements.

Other Test Event (OTE) (Not Applicable to RAM). Events not applicable to RAM evaluation of the system.

Performance Limitation. Inability of a system to meet performance specifications without incurring a malfunction. The classic example is a vehicle with a speed requirement of 90 miles per hour (mph). However, the design of the drivetrain prevents the vehicle from ever reaching the required speed. No malfunction has occurred which prevents the achievement of the required speed.

Pre-test/Post-test Checkout. Events observed during burn-in, pre-test/post-test inspection, or other pre-test/post-test activities.

B-3

Preventive Maintenance, Checks and Services (PMCS). Maintenance actions of a preventive nature normally performed by operator or crew.

Primary Failure. Category for failure events caused by an earlier or concurrent primary failure.

This category applies to those events scored as dependent failures.

Rapidly Recoverable Event (RRE). Minor events corrected by the operator/crew within 30 minutes will be scored as Rapidly Recoverable Events (RRE) if the repair procedure is identified in the operator’s manual and is performed using only on-board tools and repair or spare parts.

More than 3 RRE during a mission will be scored on their own merit. The event would normally be scored at a higher level (SA or EFF); however, because the failure can be rectified rapidly it is scored as a RRE.

Reliability. Probability that an item can perform its intended function without failure for a specified time interval under stated conditions.

Reliability Event. This category captures any test incidents that document failure or malfunction of an item.

Reliability Event Chargeability. Section of the scoring criteria documenting the root cause of a failure.

Routine Operating Procedures (ROP). Operating procedures routinely performed by the operator & prescribed in the user manual. Typically, they are tasks the operator or crew may quickly perform and are not reliability failures.

Scheduled Maintenance. Maintenance actions performed by a maintainer in accordance with applicable technical documentation/manuals.

Software. This chargeability category includes all incidents attributable to software contained within the system (application, interface, or firmware). This category may be broken down further into software that is “Contractor Furnished Equipment (CFE)” and “Government Furnished Equipment (GFE)” Software.

Support Equipment. Chargeability category for incidents caused by special tools, common tools, Test Measurement and Diagnostic Equipment (TMDE), software programs, or other equipment not a component of the operational system.

System Abort (SA) A System Abort is an event that results in the loss or degradation of an essential function(s) that renders the system unable to enter service or causes immediate removal from service (a SA may result in a “Not Mission Capable” status under wartime conditions, or reduces its utility to the point that it is deemed ineffective/unsafe in its role on the battlefield). System abort also includes those events that create a Category I (catastrophic) or II (critical) hazard as defined in MIL-STD-

882. By definition all System Aborts (SA) are also EFFs

B-4

Technical documents/Manuals. This chargeability category includes all events that are attributable to misleading, incorrect, or nonexistent-but-needed information in the technical documents/manuals.

Test Peculiar. Malfunctions caused by outside equipment not part of the system under test or people not acting as test players (crew or maintenance personnel). Engineering evaluations to analyze the cause of test peculiar malfunctions, as well as any malfunctions and/or maintenance efforts caused by the engineering evaluation are scored as "OTE". This also includes maintenance evaluations conducted as a part of the test plan and malfunctions to or caused by test peculiar instrumentation.

Training. This includes any event attributed to inadequacies in training due to omitted or incorrect training procedures, or inappropriate training material such as information above the general level of understanding of the target audience.

Unrelated Damage. This includes damage caused by natural phenomena (e.g., lightning, earthquakes, etc.) or other influences beyond control of the operational elements of the system.