DI-MISC-80759B

Acceptance Test Equipment (ATE) Validation Plan

The ATE Validation Plan provides the philosophy, test logic, sequence and test schedules, and test procedures used in the development, acceptance, and control of the Acceptance Test Equipment.

Approval DateApril 7, 2022

AMSC NumberN6735

Preparing Activity—

Project NumberMISC-2021-013

OPRMI

DTIC ApplicableNo

GIDEP ApplicableNo

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Supersedes

DI-MISC-80759ADI-QCIC-80757ADI-QCIC-80922A

DI-SESS-81004

Description & Purpose

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Application & Interrelationship

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Use & Relationship

The ATE Validation Plan provides the philosophy, test logic, sequence and test schedules, and test procedures to be utilized in the development, acceptance, and control of the Acceptance Test Equipment (ATE).

a. This Data Item Description (DID) contains the format and content preparation instructions for the data product generated by the specific and discrete task requirement as delineated in the contract.

b. This DID is applicable to acquisitions of military systems, equipment, and components that require the use of acceptance test equipment to achieve the acceptance of Military items and the traceability to that items technical data requirements.

c. When this DID is imposed in a contract or purchase order, the procuring activity must ensure that DI-SESS-81004, Special Inspection Equipment (SIE) Engineering Design Data and Associated Lists is applied at the appropriate level. When ATE is used by a Depot, then use full application of the DID; otherwise use as a guide.

d. This DID supersedes DI-MISC-80759A, DI-QCIC-80757A, and DI-QCIC-80922A.

Preparation Instructions

1Content.The ATE Validation Plan shall include the ATE Concept, Pre-Validation Activities, Validation Procedure, and Validation Certification. The ATE Validation Plan shall also include a Compliance Matrix that traces the ATE capabilities to test the product acceptance requirements, and a proposed Fault List as Appendices.

2Format.The ATE Validation Plan format shall be in accordance with the following Validation Plan sample:

2.1ATE ConceptThe Acceptance Test Equipment Concept details design performance calibration and accuracy requirements information to be used for screening and approval of recommended ATE prior to design and fabrication of the ATE. It is used in design control to screen each proposed design against the procuring activities' existing inventory of equipment to satisfy the requirement; maintain management control over the efforts of the contractor in the area of inspection equipment; and assure integration of design of acceptance inspection equipment. The ATE Concept format shall be contractor selected and include the following:

2.1.1Physical Description

2.1.2Functional Description

2.1.3Equipment Options (including costs)

2.1.4Concept sketch of equipment

2.1.5Block diagrams

2.1.6Requirements for calibration equipment external to the ATE

2.2Pre-Validation Activities

2.2.1Theory of OperationThe Contractor shall provide a summary of how the ATE is intended to be used and how it operates to perform its intended function before validation.

2.2.2Test Equipment HW/SW and Procedures to be ValidatedThe Contractor shall provide in advance of validation the list of all test sets, software, drawings, ATP/Calibration procedures and any other document that will be validated and placed under configuration control.

2.2.3Test Schedule and Contractor Cognizant EmployeesThe contractor shall provide a schedule of events/activities for the government validation procedure and a list of cognizant employees for each activity.

2.2.4Internal Verification (Prove-in)The Contractor shall conduct an internal verification before government validation to ensure that the test equipment to be validated demonstrates that it performs to its intended function. Data collected during this activity will be reviewed and may be used as part of the repeatability analysis.

2.2.5Acceptance Limits for Performance CapabilitiesThe Contractor shall provide a list of the applicable documents and drawings that contain the testing requirements including the contract number and MIS number. The Contractor shall trace the MIS SPEC requirements against the test set testing capabilities. The Contractor shall generate a requirement vs. SW modules compliance matrix (See Appendix A as an example). This will be performed by tracing software test modules to each of the requirements in the applicable system or component performance specification and the applicable drawings, if any. (A test module is considered to be the source code for a given test requirement). The matrix can be generated in advance and verified at validation.

2.3Validation ProcedureThis section could be used as a Validation Checklist.

2.3.1Entry meeting activities

2.3.1.1Review the test station's theory of operation.

2.3.1.2Verify that the test set has undergone an internal verification and it has been accepted by the proper department/organization.

2.3.1.3Review data collected during test station's internal verification or prove-in.

2.3.1.4Check on status of "Golden Units" (review data).(A Golden Unit is defined as a unit under test (UUT) that has been certified as a good unit by an approved or validated acceptance test set).

2.3.2Software activities

2.3.2.1Verify that software documentation has been properly signed off (internal verification).

2.3.2.2Verify that the software is under configuration control IAW established procedures.

2.3.2.3Review and verify the requirement traceability/Compliance Matrix.

2.3.3Configuration Audit (HW/SW) Activities

2.3.3.1Review the cable interconnects and overall station setup vs. the test set drawing package.

2.3.3.2Perform schematic traces of all test requirements(i.e., how are the connections made to perform given test to a given requirement, to include the software module that requests the test). Depending on the number of tests, this could be performed on a sample basis.

2.3.4Calibration Activities

2.3.4.1Review and verify the test set calibration procedures (if any).

2.3.4.2Verify test set overall calibration sticker is in place.

2.3.4.3Verify that individual instruments are calibrated and clearly show their corresponding calibration stickers.

2.3.4.4Review test equipment test error analysis.

2.3.4.5Review contractor's calibration recall system.

2.3.5Test Set Activities

2.3.5.1Perform a software up-load from the software configuration management libraries(i.e., web site, disc, CD, etc.).

2.3.5.2Verify that the test procedure (TP)/operating instructions (OI) have been signed off by the proper departments/organizations.

2.3.5.3Baseline runsPerform a baseline run by running a complete functional test with a known golden unit by following all the steps in the TP/OI. If a golden unit is not available, proper arrangements should be made for an appropriate substitute before on-site validation. The paragraphs on the TP/OI will be used for test cross-reference and should be added to the Compliance Matrix (Appendix A).

2.3.5.4Fault insertionThis step will verify that the test set(s) can identify faults in the UUT. The Contractor shall provide up to ten non-destructive faults before the on-site validation. The Government representative has the option of using all of the contractor's generated faults or select their own. Each fault insertion will be followed by a "good run" (only for that particular test). The data from the good runs can be used later for the repeatability step. These runs will be conducted at ambient temperature.

2.3.5.5RepeatabilityAfter all fault insertion has been performed, another baseline run will be performed at the option of the Government representative. This data, along with the previous gathered data, will be used to determine the repeatability of the test set(s).

2.3.6Configuration Control

2.3.6.1At the completion of Government validation, the test set documentation (HW/SW) shall be under the same configuration control as the product documentation.

2.3.6.2At the request of the Government representative, the Contractor shall explain their configuration control procedures as they apply to the test set's software and hardware IAW their written procedures.

2.3.7Validation Process/Results

2.3.7.1The Government representative and Contractor personnel should have a meeting at the end of each day of validation to discuss how the validation is proceeding.Any problems that occurred that day should be discussed to determine impact to the validation. If no problems were discovered, the attending members should discuss the next day's agenda.

2.3.7.2Once all validation activities have been completed, ensure that the test station is placed under strict configuration control and tamper proof seals are placed on the validated test set.

2.3.7.3As part of the validation process, the following shall be considered

2.3.7.3.1Test set maintenance spares.

2.3.7.3.2Establish maintenance records and schedules for the test set.

2.3.7.3.3Ensure all maintenance performed on the station shall be recorded as performed.

2.3.7.4Unless contractor has a procedure in place that follows all test set activities, a logbook that shows all the above work shall be generated.

2.4ATE Validation Certification

2.4.1Validation DataThe Government representative will compile all validation data for review and approval. The Government validation is deemed complete when the following is satisfied:

2.4.1.1All test equipment documentation has been properly signed off by the Contractor's quality engineering activity and placed under configuration control.

2.4.1.2The test equipment has demonstrated that it does perform to its intended function.

2.4.1.3A compliance matrix has been generated and covers all the acceptance requirements of the UUT.

2.4.1.4All action items generated during validation are resolved and closed or a path forward has been identified.

2.4.2ATE Validation Certificate

2.4.2.1Once all test equipment validation requirements are satisfied, a validation certificate attesting to the successful validation of the test equipment will be issued.The validation certificate should be signed by all personnel involved in the validation activities.

2.4.2.2The validation certificate will be valid until such time that changes are made to the test set HW/SW and/or procedures.At such time, the Government reserves the right to re-validate the test set. The validation certificate will remain with the corresponding test set as proof that the test equipment is adequate for hardware acceptance.

References

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Figures

Figure Appendix A. Appendix A: Compliance Matrix

Figure Appendix B. Appendix B: Fault Insertion Check List

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