DI-SESS-82289

Failure Data and Traceability Record

Summarizes field and depot test results and repair information, including component replacement data, failure causes, and traceability of repaired subassemblies to the missile section they were removed from.

Approval DateAugust 21, 2019

AMSC NumberN10076

Preparing ActivityAS

Project NumberSESS-2019-033

OPR—

DTIC Applicable—

GIDEP Applicable—

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

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

Supersedes

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Description & Purpose

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Application & Interrelationship

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Use & Relationship

This database summarizes both the field test results and incoming depot test results. This data item provides repair information with incoming fail codes and component replacement information including part number and serial number. The replaced serialized components and/or subassemblies are identified for every missile section submitted for repair. This database also cites which of those components was believed to be the cause of failure for each failed subassembly removed/repaired in the missile section. It also cites if the field failure was confirmed, if a secondary failure was found, if section modification/upgrade occurred, and whether or not the repair was a warranty repair. The repair of removed subassemblies will be reported so that they are directly traceable to the missile section from which they were drawn.

This Data Item Description (DID) contains the format, content and intended use information for the data deliverable resulting from the work task described in the contract.

Preparation Instructions

1Reference documentsThe applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2Format

2.1MediaThis data item shall be made accessible via an integrated digital environment (IDE) database. Summary Reports from the data extractable database will be accessible via Microsoft Excel. The list of data fields for the data extractable database are listed below:

2.2Fieldnames for Data Extractable Database1. Type Item (GS, CS, card) (H) 2a. Incoming Part Number (H) 2b. Outgoing Part Number (H) 3. Item Serial Number (H) 4. Item NSN Incoming 5. Item NSN Outgoing 6a. Item Nomenclature Incoming 6b. Item Nomenclature Outgoing 7. Contract number (H) 8a. Order/Mod 8b. CLIN 9. Customer (H) 10. Received Date (H) 11. Received From 12. Received From UIC 13. Field Reported Discrepancy 14. Shipped Date 16. UNCR (H) 17. DD250 Number 18. DD250 Date 19. AHR (H) 20. Induction Date 21. GS ETM: In (H) 22. GS ETM: Out 23. GS S/W: In 24. GS S/W: out 25. CS ETM-1: In 26. CS ETM-1: Out 27. CS ETM-2: In 28. CS ETM-2: Out

2.3Reason for ReturnInclude following: 29a. GS serno 29b. CS serno 30. Failure Codes 31. Symptom Analysis (As Required) 32. Comments (As Required)

2.4Depot Failure VerificationInclude following: 33. Test set type/number 34. Test File Number (H) 35. Failure Codes (H) 36. Symptom Analysis (As Required)

2.5Depot Repair for each subassembly/lower level part (even non-serialized parts)Removed or installed list the following: 37a. Name of subassembly removed (H) 37b. Name of subassembly installed (H) 38a. Removed Part Number (H) 38b. Installed Part Number (H) 39a. Removed Serial Number (H) 39b. Installed Serial Number (H) 40a. Removed NHA name (H) 40b. Installed NHA name (H) 41a. Removed NHA Part Number (H) 41b. Installed NHA Part Number (H) 41c. Removed NHA Serial Number (H) 41d. Installed NHA Serial Number (H) 42. Delete-reserve number (H) 43a. Repair Type (H) 43b. Repair Remarks-exceptions (As Required) 44. Repair Action Comments 45. Fault Isolation/Failure Analysis 46. Delete-reserve number 47. Modifications/Upgrades (As Required)

2.6Depot Repair Verification48. Test File Number 49. ETI (H) 50. Test Set type and number 51. S/W tested with 52. Test Result Outgoing (pass/fail) Note: The letter "H" designates an historical data field.

2.7Record SequencingThe data shall be represented by a Header Record for each equipment and for each different type of test performed, in addition to Records 1 and 2 for each failure that occurs. Records 1 and 2 shall immediately follow the associated Header Record. The data shall be sequenced in order for their Header number and Failure Number.

2.8LabellingThe media shall contain a label stating the time period that the data represents, contractor name, contract number, program name, point of contact and the numbers of the first and last Header numbers contained on media.

3Content

3.1Header RecordA Header Record is required for each unit tested and every type of test being performed, whether or not any failures were detected. For example, if twenty-five equipment are to be built, and are to be subjected to Burn-In, Contractor Acceptance, and Probability Ratio Sequential Test (PRST) tests only, twenty-five Header Records, representing each equipment, are required for Burn-In, twenty-five Header Records are required for Contractor Acceptance, and a Header Record is required for each equipment selected to go through PRST. All data shall be left justified within the fields unless specified otherwise. If the data is not applicable or not available, N/AP and N/AV should be used respectively. No fields should be left blank. Each Header Record shall contain the following eleven fields:

3.1.1Field 1 (Cols. 1-6) Header NumberEnter the number of the Header Record. This number will begin at 000001 (for the first Header Record prepared) for each type of test and be incremented by one each time a different Header Record is prepared. For example, if a contract calls for testing to be done for Burn-In, Contractor Acceptance, Reliability Qualification Test (RQT), and PRST, a Header Record with the Header number 000001 will be prepared for each of these types of tests. No two numbers shall be the same within a type of test. The data in this field shall be right justified and zero filled.

3.1.2Field 2 (Cols. 7, 8) Failure NumberThis field will be zero filled.

3.1.3Field 3 (Cols. 9-28) Part Number of Unit TestedEnter the part number for the unit (e.g., equipment, nomenclature assembly) being tested as it appears in the engineering documentation. If the equipment under test has various configurations, the appropriate dash number to exactly identify the specific configuration shall be included as part of the part number. Any National Security Agency (NSA) drawing in the engineering documentation shall begin with the characters 0N (the first character is a numeric zero).

3.1.4Field 4 (Cols. 29-34) Serial NumberEnter the serial number of the unit under test and right justify the data in this field. This field shall contain only integer values.

3.1.5Field 5 (Cols. 35-54) Contract NumberEnter the contract number for the contract under which this data is being prepared. An example is N00019-15-D0034.

3.1.6Field 6 (Cols. 55-60) Beginning DateEnter the date for the first day the equipment is being tested for a particular type of test. The year shall be entered in columns 55 and 56, a two-digit number for the month shall be entered in columns 57 and 58, and the day of the month shall be entered in columns 59 and 60. For example, the proper code for 9 November 2019 would be 191109. This field shall contain only integer values.

3.1.7Field 7 (Col. 61) Test CodeA list of test codes to be used are found in Table 1.

3.1.8Field 8 (Cols. 62-67) Ending DateEnter the date that the equipment completed a particular type of test. Do not enter the date the equipment failed (unless it also completed the test that day). The data shall be coded as specified for Field 6.

3.1.9Field 9 (Cols. 68-75) Duration of TestEnter the total number of hours of testing that the unit was submitted to the conditions of a particular type of test before completion. This time does not include the time the unit was in other types of tests or troubleshoot time. The number shall be entered with the decimal point in column 73, and the tenths of the hour entered in column 74 and 75.

3.1.10Field 10 (Cols. 76-79) Blank FieldThese columns shall be left blank.

3.1.11Field 11 (Col. 80) Record ControlThe letter H shall be entered in this column.

3.2Failure Data RecordA Failure Data Record (consisting of Records 1 and 2 below) is required for every failure detected during testing.

3.2.1Record 1Record 1 of each entry shall contain:

3.2.1.1Field 1 (Cols. 1-6) Header NumberEnter the number that appears in Field 1 on the Header Record. This number will link the Failure Data Record with its associated Header Record. The data in this field will be right justified and zero filled.

3.2.1.2Field 2 (Cols. 7-8) Failure NumberThis number will begin at 01 for the first failure of a particular unit for each specific type of test and is incremented by one each time another failure occurs. If two or more parts fail at the same time, a Failure Data Record is completed for each failure and each is assigned a unique failure number.

3.2.1.3Field 3 (Cols. 9-24) Failed Part NumberEnter the part number, as it appears in the engineering documentation, for the part in which the failure has occurred. Any NSA drawing in the engineering documentation will begin with the characters 0N (the first character is the numeric zero).

3.2.1.4Field 4 (Cols. 27-31) Part Reference DesignatorEnter the part reference designator for the failed part (e.g., R1, CR4, C5, etc.).

3.2.1.5Field 5 (Cols. 32-46) Subassembly Part NumberEnter the part number for the subassembly on which the failed part is used. The number should be entered as it appears in the engineering documentation to include any dash numbers in the case of tabulated assemblies. Any NSA drawing in the engineering documentation will begin with the characters 0N (the first character is a numeric zero).

3.2.1.6Field 6 (Cols. 47-51) Nomenclatured Subassembly Reference DesignatorEnter the reference designator for the nomenclature subassembly on which the failure was detected. Include any appropriate dashes (e.g., E-EDT).

3.2.1.7Field 7 (Cols. 52-57) Nomenclatured Subassembly Serial NumberEnter the serial number of the nomenclature subassembly identified in Field 5 above. Right justify the data within the field. This field shall contain only integer values.

3.2.1.8Field 8 (Cols. 58-66) Equipment NameEnter the name of the equipment and/or ancillary (e.g., KG-84, KY-65, RCU, etc.).

3.2.1.9Field 9 (Cols. 67-72) Equipment Serial NumberEnter the serial number of the unit under test. Data should be right justified.

3.2.1.10Field 10 (Cols. 73-78) Date of FailureEnter the date on which the failure was detected. Use columns 73 and 74 for the year, columns 75 and 76 for the month and columns 77 and 78 for the day of the month. This field shall contain only integer values.

3.2.1.11Field 11 (Col. 79) Test CodeA list of the test codes to be used are found in Table 1.

3.2.1.12Field 12 (Col. 80) Record ControlEnter the numeral 1 in this column.

3.2.2Record 2Record 2 of each entry shall contain:

3.2.2.1Field 13 (Cols. 1-6) Header NumberEnter the number that appears on the Header Record in Field 1 on Record 1. The data in this field will be right justified and zero filled.

3.2.2.2Field 14 (Cols. 7-8) Failure NumberEnter the number that appears in Field of Record 1. The data in this field will be right justified and zero filled.

3.2.2.3Field 15 (Cols. 9-13) Vendor CodeEnter the Commercial and Government Entity (CAGE) five digit code (per Federal Supply Code for Manufacturers handbook, H4-1 and H4-2) for the manufacturer of the failed part.

3.2.2.4Field 16 (Cols. 14-30) Manufacturer's Part NumberEnter the manufacturer's part number for the failed part. Any NSA drawing in the engineering documentation will begin with the characters 0N (the first character is a numeric zero).

3.2.2.5Field 17 (Col. 31) Test CodeA list of the test codes to be used are found in Table 1.

3.2.2.6Field 18 (Cols. 32-36) Date Lot CodeEnter the date lot code for the failed part.

3.2.2.7Field 19 (Cols. 37-43) Test Time to FailureEnter the total length of time in hours that the unit was subjected to the conditions of that type of test before it failed. The decimal point shall be placed in column 41. If more than one failure occurs in a type of test, the time to failure is cumulative. For example, if an equipment failed after 20 hours of burn-in testing, was fixed, put back into Burn-In, and failed again 55 hours later, then one Header Record would be prepared for the equipment to show it went through burn-in and the first Failure Record would show "Time to Failure" as 2 hours and the second Failure record would show 75 hours in "Time to Failure."

3.2.2.8Field 20 (Cols. 44-74) Failure DescriptionEnter any information necessary to describe the failure. If abbreviations are used, they should conform to ASME Y14.38. The contractor is responsible for deciding on the words to be used. In the event the failure was caused by workmanship, test equipment, or the cause could not be determined, use one of the following respectively: WORKMANSHIP, TE, CNV.

3.2.2.9Field 21 (Cols. 69-74) Trouble Failure Report NumberEnter the Trouble Failure Report Number.

3.2.2.10Field 22 (Cols. 75-79) Temperature at FailureEnter the temperature at which the failure occurred. Enter either a plus (+) or (-) in column 75. Enter the temperature in columns 76-78 and either an "F" for Fahrenheit or a "C" for Centigrade in column 79. Right justify and zero fill the temperature in columns 76-78.

3.2.2.11Field 23 (Col. 80) Record ControlEnter the number 2 in this column.

3.3Summary Report

3.3.1ContentThe Summary Report shall include all units shipped in the prior calendar month, in repair, DD-250'd, and awaiting induction accountable to the contract.

3.3.2StructureItem # Description of Item (Items numbered for reference purposes) 16a. Section P/N 16b. Section S/N 16c. Date of Receipt 16d. Customer 16e. Contract Number 16f. Order Number 16g. CLIN 16h. Field Discrepancy 16i. Induction Date 16j. Repair Status 16k. Repair completion date 16l. Condition Code 16m. Actual Ship Date 16n. DD 250 Number 16o. DD 250 Date 16p. Repair type (repair/warranty)/UNCR/NRP

References

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Figures

Figure 1. Type of test code.

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