Attachment_0003_Aviation_Product_Verification_Audit_Requirements_W58RGZ-16-R-0158.pdf

AMCOM

Regulation 702-2

Product Assurance

Aviation Product Verification Audit Requirements

Headquarters U.S. Army Aviation and Missile Command Redstone Arsenal, AL 35898-5000 15 December 2000

UNCLASSIFIED

W58RGZ-16-R-0158

Attachment 0003

DEPARTMENT OF THE ARMY

HEADQUARTERS, UNITED STATES ARMY AVIATION AND MISSILE COMMAND

Redstone Arsenal, Alabama 35898-5000

AMCOM REGULATION 702-2 15 December 2000

Product Assurance

AVIATION PRODUCT VERIFICATION AUDIT REQUIREMENTS

FOR THE COMMANDER:

EDWARD L. STONE

Colonel, OD Chief of Staff

OFFICIAL:

//s//

LINDA B. READUS

Secretary of the General Staff

HISTORY. This was previously issued as AVSCOM Regulation 702-1 that is no longer valid.

This is the first issue of this subject as an AMCOM regulation.

SUMMARY. This covers the policies and procedures for the insertion of Product Verification Audits (PVA) into overhaul work directives, maintenance data packages, and contract documents.

APPLICABILITY. This regulation applies to the AMCOM Acquisition Center, Integrated Materiel Management Center, and Aviation and Missile Research, Development, and Engineering Center.

PROPONENT AND EXCEPTION AUTHORITY. The proponent of this regulation is the Aviation and Missile Research, Development and Engineering Center, ATTN: AMSAM-RD-SE-QM, Redstone Arsenal, AL 35898-5000. Only the proponent has the authority to approve exceptions to this regulation.

INTERNAL CONTROL SYSTEMS. This regulation does not contain internal control provisions as outlined in the Management Control Evaluation Process.

AMCOMR 702-2

SUPPLEMENTATION. Further supplementation is prohibited without prior approval of U.S.

Army Aviation and Missile Command, ATTN: AMSAM-RD-SE-QM, Redstone Arsenal, AL 35898-5000.

SUGGESTED IMPROVEMENTS. Users are invited to send comments and suggested improvements on DA Form 2028 (Recommended Changes to Publications) to Commander, U.S Army AMCOM, ATTN: AMSAM-RD-SE-QM, Redstone Arsenal, AL 35898-5000.

DISTRIBUTION. This publication is approved for public release, distribution unlimited.

SUPERSESSION. This regulation supersedes AVSCOM Regulation 702-1, dated 5 February 1985.

CONTENTS (Listed by paragraph number)

PURPOSE – 1

PROCEDURES - 2

BACKGROUND - 3

RESPONSIBILITIES - 4

APPENDIX A – Product Verification Audit Requirements

1. PURPOSE. This regulation establishes/assigns responsibilities for insertion of PVA procedures into overhaul work directives, maintenance data packages, and contract documents along with procedures and instructions to be applied in performing PVAs during overhaul, maintenance, modification kit installation, rework, and/or remanufacture of AMCOM materiel. A PVA may also apply to manufacturing and new procurement contracts, where First Article Test is not considered practical due to the complexity of the procured item/assembly.

2. PROCEDURES.

a. The procedures prescribed in this regulation relate to newly procured items and the repair/overhaul of AMCOM materiel and supplement, but do not supplant, supersede, or nullify any requirements contained within the contract, specific overhaul work requirements, other technical publications, or directives issued by AMC or this command. The provisions of this regulation do not relieve the Department of Defense, the commercial contractor, or other quality assurance elements of their responsibility for assuring that production items conform to established quality standards.

b. The PVAs are management tools used for the validation and evaluation of the conformance of items to procedural and technical requirements. The PVA will not be used as a routine means of sampling or evaluating normal quality control operations.

c. The PVA procedures are contained in Appendix A and copies will be provided to all interested parties upon request.

d. Requirements for the accomplishment of PVAs are to be incorporated into work directives, maintenance data packages, and contract documents for new procurements, overhaul, or maintenance of AMCOM materiel, when applicable.

3. RESPONSIBILITIES.

a. The Engineering Directorate, AMRDEC, will:

(1) Establish and monitor the Command’s PVA program.

(2) Determine the need for accomplishing PVA investigation of reported failures and/or customer complaints.

(3) Determine the need for, and application of, PVA requirements for newly procured items or items subject to overhaul.

(4) Provide all required PVA provisions and requirements to the AC, as a part of the procurement package, or to the IMMC, for inclusion into the Maintenance and Overhaul (M&O) requirements data package.

(5) Review work requirements, maintenance data packages, procurement documents, and technical manuals pertaining to new procurement and the overhaul or maintenance of all AMCOM-managed items to determine the need for PVA requirements.

(6) Coordinate PVA requirements with interested Command elements.

(7) Provide the applicable Weapon System Management Officer, Weapon Systems Directorate, Program Executive Office, or Program/Project Manager a copy of the PVA report(s) for their assigned systems. Collect and analyze PVA data for dissemination to interested Command elements.

(8) Provide Quality Assurance Specialists to perfo rm the PVA. Represent the Command on all PVAs performed at maintenance, overhaul, and production facilities worldwide, unless delegated.

(9) Approve or disapprove requests received from maintenance, overhaul, and production facilities regarding the frequency, change, or waiver of PVA requirements.

(10) Perform a continuous review and maintain current audit procedures and requirements.

b. The Acquisition Center will:

AMCOMR 702-2

(1) Assure that applicable PVA requirements and procedures are incorporated within contracts by including PVA provisions and requirements as provided in the procurement package.

(2) Coordinate contract PVA requirements with the Engineering Directorate, AMRDEC.

(3) Execute contract modifications or award new contracts necessary to address issues that may result from the PVA.

(4) Obtain the written concurrence/nonconcurrence from the Engineering Directorate on any proposed audit waiver(s).

c. The Integrated Materiel Management Center will:

(1) When developing procurement work directives (PWDs) or M&O data packages, insert PVA requirements for AMCOM materiel by reference to and attachment of Appendix A, when applicable. Electronic Data Interface format will be utilized.

(2) When developing PWDs or M&O data packages, request PVA requirements from the Engineering Directorate by forwarding a Data Call.

(3) When requested by the Engineering Directorate, direct organic maintenance overhaul facilities to perform audits for investigation of reported failures and/or customer complaints.

(4) Provide personnel to participate in scheduled PVAs at maintenance overhaul facilities upon request by Engineering Directorate.

(5) Furnish complete technical package with PVA procedures incorporated to requesting Command elements.

(6) Coordinate technical documents containing PVA requirements with the Engineering Directorate prior to publication.

(7) Provide funding for organic support of PVA.

APPENDIX A

PRODUCT VERIFICATION AUDIT REQUIREMENTS

FOR DEPOT, DOD MAINTENANCE ACTIVITIES, AND COMMERCIAL

CONTRACTORS

1. PURPOSE. This Appendix contains procedures and instructions to be applied in performing Product Verification Audits (PVA) during overhaul, maintenance, modification kit installation, new procurement, rework, manufacturing, and/or remanufacture of AMCOM materiel. The issuance of this appendix does not supersede instructions contained in depot overhaul work requirements, commercial overhaul manuals, or other applicable documents. It does not relieve the applicable facility from maintaining a quality system that will assure production items conform to contractual/program requirements.

2. APPLICABILITY. This procedure applies to any organization, government, or commercial, that produces a product for AMCOM.

3. DEFINITIONS.

a. Product Verification Audit. The physical examination, functional testing, disassembly, inspection, reassembly, and resetting of an item so that full determination of conformance to specifications can be verified. The audit will also include correction of defect(s) noted during the audit.

b. Contractor. Any government depot or facility or any commercial contractor that provides a service or product to AMCOM.

c. Cognizant Quality Assurance Representative (QAR). The DOD or government quality element having direct responsibility for assuring the quality of the items produced by the contractor.

d. Product Verification Audit On-site Team. The on-site team shall be comprised of individuals from the appropriate AMCOM, contractor, and/or QAR elements necessary to perform the audit and determine the adequacy of all processes, procedures, and/or corrective actions being evaluated. Normally the PVA Team Chairman is a representative from the AMCOM RDEC Engineering Directorate (ED).

e. Product Verification Audit Support Team. The support team shall be comprised of individuals from the appropriate AMCOM elements necessary to address and resolve issues that arise during the PVA. Support team shall be comprised of representatives from the ED and representatives from other directorates as determined by the PVA chairman. Unless otherwise specified in this regulation, or specifically requested by the ED, support team members will not be required to be on-site at the audited activity’s facilities.

AMCOMR 702-2(APPENDIX A CONTINUED)

f. Procuring Contracting Officer (PCO). Person with the authority to enter into contracts and make related determinations and findings.

g. Defect. Any discrepancy or nonconforming condition noted in materials, practices, processes, or procedures.

h. Recurring Deficiency. A defect identified in the current and one or more previous PBAs.

4. GENERAL. Classifying Defects. Defects noted during the audit will be classified in accordance with (IAW) the following: (Please note that any defect caused during the unpacking, depreservation, testing, disassembly, or inspection process of the PVA, which would not have occurred had proper care been taken, will also be written as defects.)

a. Critical Defect. A defect that would result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product or a defect likely to prevent performance of a major end item, or major part thereof.

b. Major Defect. A defect, other than critical, that is likely to result in failure, or to reduce materially the usability of the product for its intended purpose.

c. Minor Defect. A defect or a departure from established standards that are not likely to reduce materially the usability of the product for its intended use or operation of the unit.

d. Observation. A condition or circumstance that is noted during the PVA that does not currently meet the aforementioned criteria but holds the potential of causing a defect in the future.

5. DEFECTS. Defects discovered during the PVA will be documented by the PVA Team Chairman by using the “Finding Report Sheet” (enclosure 1). The PVA Team Chairman will provide copies of each finding to the contractor quality assurance element and the cognizant government QAR. This will allow immediate actions to begin in the resolution of the defect.

Further actions outlined below pertain to defects.

a. Observation. In the event an observation-type defect is discovered the following actions will be taken:

(1) The PVA Team Chairman will notify appropriate agencies/offices, in a timely manner, utilizing the PVA Finding Report Sheet.

(2) The contractor is not required to provide a written response, but is encouraged to do so.

b. Minor. In the event a minor defect is discovered, the following actions will be taken:

(1) The PVA Team Chairman will notify appropriate agencies/offices, in a timely manner, utilizing the PVA “Finding Report Sheet.”

(2) The contractor will isolate the cause of the defect and initiate corrective actions.

(3) All minor defects/findings will require a written response addressing corrective actions taken and actions taken to prevent recurrence.

(4) In the event a minor defect is a recurring deficiency, regardless of weapon system or date when original discrepancy was noted, it will be written into the report as a minor defect, but the corrective actions required below for a major defect will apply.

c. Major. In the event a major defect is discovered, the following actions will be taken:

(1) The contractor will halt production at the responsible station until corrective action is acceptable to AMCOM.

(2) The contractor will provide the QAR information reflecting the total quantity shipped and to what destination pertaining to any item that could contain the identified defect.

(3) The contractor will determine impact of defect on products previously delivered under this contract, if any, and initiate corrective action to address those units at no additional cost to

AMCOM.

(4) The contractor will isolate the cause of the defect and initiate corrective actions. All findings will require an in-depth written response outlining corrective actions to prevent recurrence.

(5) The contractor will review work documents for the specified operation responsible for the defect to ascertain that they are complete, adequate, and sufficiently defined to assure that, if followed and completed by both production/maintenance and inspection personnel, they will provide objective evidence of a quality operation.

(6) The contractor will assure the cognizant QAR and the AMCOM PVA Team Chairman that positive, effective, corrective action has been completed that will prevent recurrence of the cited defect. This assurance can be verbal at first, in order to facilitate continuing production.

However, a written report from the contractor quality element containing all corrective actions completed and actions taken to prevent recurrence will be provided to the QAR and the AMCOM PVA Team Chairman within 24 hours after the verbal response.

(7) In cases of depot repair, the AMCOM PCO/QAR may refuse acceptance of the defective and/or suspect item(s).

(8) The PVA Team Chairman will notify appropriate AMCOM agencies/offices in a timely manner, such as furnishing a copy of the trip report or PVA finding. In addition, the PVA Chairman will notify the PCO and the Program Manager, Weapon System Manager, or the Program Executive Officer. The PVA Chairman will use his/her judgment to determine the urgency/nature of this notification, based on the impact of the defect on the weapon system.

d. Critical. In the event a critical defect is discovered, the following actions will be taken:

(1) All actions outlined in paragraph 5.c. above will be completed.

(2) The PVA Team Chairman will notify the AMCOM Safety Office if deemed necessary.

(3) Upon request, the contractor will provide the AMCOM Safety Office with technical information necessary for the issuance of a Safety of Flight Message or Aviation Safety Action Message to the field (if necessary).

(4) Government acceptance/release of product will cease immediately until corrective actions are acceptable to the contracting officer.

6. SCHEDULED PVA FREQUENCY.

a. The contractor will notify AMCOM of readiness to perform the PVA in advance of the scheduled PVA start date IAW paragraph 7.b.(2). The frequency for performing subsequent PVAs will be stated in the contract or in the absence of a firm contract (i.e., organic depot) the frequency will be as specified by the ED and/or the PCO.

b. Contractors may request to delay scheduled PVAs in frequency or waive PVA requirements of selected items in cases where accumulated objective evidence indicates that a consistent quality item is being produced. The Command’s actions will be based on the overall performance history, failure impact, supply impact, length of program, and nonscheduled PVAs accomplished by the ED. Like or similar items may be grouped for these purposes provided concurrence is obtained from AMCOM RDEC ED.

c. The contractor may be directed by the PCO to increase or decrease the scope of a PVA pursuant to the “Changes” clause of the contract.

7. RESPONSIBILITIES.

a. The AMCOM AMRDEC ED representative will act as the chairperson of the PVA On-site and Support Team. Participation by the contractor’s quality representative and the cognizant government QAR are encouraged.

b. The Contractor will:

(1) With the concurrence of the cognizant government quality element and AMCOM, schedule and perform PVA as required by the terms of the contract or as otherwise required.

(2) Notify AMCOM through the cognizant government quality assurance element, with information copy to the ED, ATTN: AMSAM-RD-SE-QM, of the date the PVA candidates will be available. Notification will be provided at least 20 working days prior to the selected date if facilities are within the Continental United States. If facilities are outside the Continental United States, notification will be provided at least 95 working days prior to the selected date to allow sufficient time for travelers to gain theater clearance.

(3) Provide technical personnel, tooling, measuring and test equipment, work area, forms, and clerical assistance, as required, to perform the PVA.

8. PROCEDURE.

a. The initial PVA will be performed on one of the first three (3) items produced; thereafter, PVAs will be accomplished IAW paragraph 6. The PVA candidate will be selected by the AMCOM PVA Team Chairman at random from the three (3) tendered for acceptance to the Government or if a government facility, from available stock. Upon completion of the disassembly and testing portion of the audit of the selected candidate, without finding any critical or major defects as defined in paragraph 5.c./5.d., the other two (2) candidates will be released as PVA candidates. In the event that a critical or major defect is found in the audit candidate, the contractor will satisfy the AMCOM PVA Team Chairman and the government QAR that such a defect does not exist in the other items prior to acceptance. For reoccurring audits, if any, the audit candidate shall be selected by the AMCOM PVA Team Chairman from all completed items currently available.

b. The item selected for PVA will be inspected for adherence to preservation, packaging, packing, and marking requirements prior to removal from the shipping container. A visual inspection and functional test will be performed prior to disassembly.

c. The PVA Team will review the production processes, procedures, tooling, and equipment used in connection with the item being audited for adequacy and conformance to the work requirements.

d. Disassembly will be performed in an area accessible only to audit personnel. Normally, audit participation will be limited to specified production and quality assurance personnel of the contractor activity, the cognizant government QAR, and the AMCOM PVA Team Chairman and team personnel.

e. Visual inspection, dimensional checks (such as backlash, end clearance, running clearance, etc.), and nondestructive testing are accomplished during and after disassembly IAW applicable technical directives. Findings are recorded for comparison with historical data and conformance evaluation. Measuring and test equipment will be reviewed for correct calibration prior to use.

f. Applicable accessories and components will be functionally tested and inspected to contractual/work specifications.

g. The item will be reassembled and functionally tested IAW applicable specifications and made ready for government acceptance including preservation, packing, packaging, marking, and update of records.

h. Conduct of the PVA will be planned in a manner that adequately allows examination/audit of all procedures involved. Each step in the process shall be analyzed to determine compliance to the specifications. It may not be logical or possible, due to time constraints, to track the same item throughout the PVA; therefore, at the AMCOM PVA Team Chairman’s discretion, examination of representative assemblies may be used as evidence of compliance to requirements. The AMCOM PVA Team Chairman will determine the scope and detail of the PVA.

i. During the course of the PVA, the PVA Team Chairman may request progress meetings to provide status to the contractor. After the PVA is completed, the AMCOM PVA Team Chairman will conduct an exit critique attended by all concerned contractor personnel. The context of the audit findings and corrective actions will be discussed and any disputes will be resolved. Findings, classifications, and corrective actions will be discussed and determinations made as to cause of defect established (i.e., workmanship, tooling, technical requirements, etc.). The contractor’s management personnel will take immediate action to correct and preclude recurrence of all defects attributable to failure to comply with requirements.

j. All defects will be recorded on the enclosed AMCOM PVA Audit Finding Record.

Corrective actions as well as actions taken to prevent recurrence will also be documented on this form. The form will be signed, as a minimum, by the contractor’s quality manager or designated representative and the AMCOM PVA Team Chairman.

9. INSPECTION RESULTS. The contractor will prepare and forward, through the cognizant government quality element, finalized audit reports within ten (10) working days after completion of the PVA to Commander, U.S. Army Aviation and Missile Command, ATTN:

AMSAM-RD-SE-QM, Redstone Arsenal, Alabama 35898-5000. The report will include:

a. Name and location of contractor.

b. Contract number or equivalent.

c. Descriptive noun, national stock number, part number, and serial number of the item being audited.

d. Summary/count of total defects, including a brief description of each:

(1) Critical.

(2) Major.

(3) Minor.

(4) Observation.

e. Complete description of each audit finding, with corrective action taken, and action taken to prevent recurrence.

f. The audit report will be signed, as a minimum, by the contractor’s quality manager or his designated representative. Objections, accompanied with explanations, on any audit finding(s) will be specifically annotated and forwarded to AMCOM for resolution.

g. The Final Audit Report will be routed through the cognizant government quality element for review prior to forwarding to AMCOM.

h. In the event that the PVA Final Audit Report is rejected, the contractor will prepare and forward a revised final audit report within 10 working days after receipt of written rejection. The revised audit report will be forwarded to the same address listed in paragraph 9 above.

i. Objection by the contractor as to the existence of a defect or as to its classification will be resolved by the AMCOM AMRDEC ED. Further nonconcurrence will be referred to the PCO for final resolution (Note for nonorganic contractors: IAW the clause entitled “Disputes” as stated in the contract.)

10. REPLY TO INSPECTION RESULTS.

a. The AMCOM Quality Representative will acknowledge receipt of the Final Audit Report and complete the following within 10 working days of receipt:

(1) Review the Final PVA Report for compliance and completeness IAW this regulation.

(2) Review the report for acceptance/rejection of corrective action and actions taken to prevent recurrence.

(3) Forward a written reply to the AMCOM PCO and/or cognizant government quality element and contractor, recommending acceptance or rejection of the Final Audit Report.

b. The PVA candidates will be shipped IAW contract delivery schedules or released to supply activity upon acceptance of the Final Audit Report.

PRODUCT VERIFICATION AUDIT FINDING REPORT

NOMENCLATURE

CONTRACT NUMBER REPORT DATE

NUMBER OF

FINDINGS

CRITICAL MAJOR MINOR OBSERVATIONS

FINDING:

REFERENCE: PVA TEAM CHAIRMAN:

ACTION TAKEN:

CONTRACTOR REPRESENTATIVE: