parts, materials, and processes control program for …

NONMEASUREMENTSENSITIVE

~&II-S-W&-1546A (USAF)

SUPERSEDINGMI L-STD-1546(USAF)Dated 12FEB 1981

MILITARY STANDARD

PARTS, MATERIALS, AND PROCESSES

CONTROL PROGRAM

FOR

SPACE AND LAUNCH VEHICLES

o@AMSC F4315 FSC 1820

DISTRIBUTION STATEMENT A Approvedforpublicrelease;distributionunlimited.

Downloaded from http://www.everyspec.com

MIL–STD-1546A (USAF)01 MAR 1988

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DEPARTMENT OF THE AIR FORCEWashington, D.C. 20330

MIL-sTD–1546A (USAF)

Parts, Materials, and Processes Control Programfor Space and Launch Vehicles

1. This Military Standard is approved for use by theDepartment of the Air Force, and is available for use by allDepartments and Agencies of the Department of Defense.

2. Beneficial comments (recommendations, additions,deletions) and any pertinent data which may be of use inimproving this document should be addressed to:

USAF Space Division, SD/ALMP. O. BOX 92960Worldway Postal CenterLos Angeles, CA 90009-2960

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by using the self–addressed Standardization Document ImprovementProposal (DD Form 1426) appearing at the end of this document orby letter.

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MIL-STD-1546A (USAF)01 MAR 1988

FOREWORD

To ensure successful operations of space equipment,attention to every detail is required at every level of assemblythroughout development, manufacture, qualification, and testing,starting with the parts, materials, and processes used. Forspace and launch vehicles, if the parts, materials, andprocesses have defects or lack the required reliability, successmay never be achieved.

Analysis of space mission failures and on orbit anomalies bythe USAF Space Division revealed that the nonavailability ofreliable space quality electronic piece parts was a seriousdeterrent to achieving apace mission success. In responding tothis problem, the Space Division Commander initiated a programwith the objective of establishing a “space quality’” level ofpiece parts for space borne missions. In addition, this standardwas developed to document the management requirements for parts,materials, and processes for space and launch vehicles.

The objective of this parts, materials, and processescontrol program standard is to ensure integrated and coordinated

●management of the selection, application, procurement, control,and standardization of parts, materials, and processes for spaceand launch vehicles. The requirements presented herein shouldreduce program costs and should improve the reliability of spaceand launch vehicles. The requirements in this standardincorporate the Parts Control Program requirements stated inMIL-STD-965, expand those requirements to satisfy space andlaunch vehicle acquisitions, and extend the requirements toaPPIY to materials and processes. This standard is applicableto all USAF Space Division contracts for new or modified designsOf sPace and launch vehicles.

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1.

1.1

1.2

2.

2.1

2.2

3.

3.1

3.1.


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PAGE

SCOPE .................................................... 1

PURPOSE ................................................. 1

APPLICATION ............................................. 1

REFERENCED DOCUMENTS ..................................... 3

GOVERNMENT Docents. ................................... 3

ORDER OF PRECEDENCE. .................................... 3

DEFINITIONS AND ACRONYMS. ................................ 5

DEFINITIONS ............................................. 5

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3.1.2

●3.1.33.1.43.1.53.1.63.1.73.1.83.1.93.1.103.1.113.1.123.1.133.1.143.1.153.1.163.1.17

Acquisition Activity.. ................................ 5Categories of Contractor .............................. 5Contracting Officer ................................... 5Electronic Part ....................................... 5JAN Class S mart ...................................... 5Lot (Material) ........................................ 5Manufacturing Baseline. ............................... 6Material .............................................. 6Military Parts Control Advisory Group (MPCAG)......... 6Off-the–shelf Item ................................... 6part .................................................. 6Parts, Materials, and Processes Control Board (PMPCB) 6Parts, Materials, and Processes Selection List (PMPSL) 6Process .............................................. 6Production Lot (Electronic Parts) .................... ~Registered PMP ....................................... 7Space Quality PMP Baseline. .......................... 7

3.2 ACROWS ................................................ 7

3.2.1 MPCAG ................................................. 73.2.2 PAR ................................................... 73.2.3 PAP ................................................... 73.2.4 PMPCB ................................................. 73.2.5 PMPSL ................................................. 7

4. GENERAL REQUIREMENTS.. .................................... 9

4.1 PARTS, MATERIALS, ANI)PROCESSES CONTROL PROGRAM

● PLANNING ................................................ 9

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CONTENTS (Continued)

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4.2 PARTS, MATERIALS, AND PROCESSES CONTROL BOARD (PMPCB) ...

4.3 MANAGEMENT OF

4.4 MANAGEMENT OF

4.5 MANAGEMENT OF

4.6 MANAGEMENT OF

PMP SELECTION .............................

PMP ENGINEERING REQUIREMENTS ..............

PARTS AND MATERIALS PROC~EMENT ...........

PARTS, MATERIALS, AND PROCESSESAPPLICATION .........................................

4.7 RADIATION HARDNESS ASSURANCE. ...........................

4.8 COMPLIANCE WITH SYSTEM REQUIREMENTS .....................

4.9 GOVERNMENT FURNISHED EQUIPMENT ..........................

4.10 OFF-THE-SHELF ITEM (EQUIPMENT) .........................

4.11 CUSTOM LARGE SCALE INTEGRATED CIRCUITS .................

4.12 VERY HIGH SPEED INTEGRATED CIRCUITS ....................

4.13 USAF SPACE DIVISION SPACE PARTS WORKING GROUP ..........

5. DETAILED REQUIREMENTS ....................................

5.1 PARTS, MATERIALS, AND PROCESSES CONTROL.PROGRAM PLANNING

5.1.1 Parts, Materials, and Processes Control Program Plan..5.1.2 Milestone Schedule. ...................................

5.2 PARTS, MATERIALS, AND PROCESSES CONTROL. BOARD (PMPCB) ...

5.2.1 Membership ............................................5.2.2 PMPCB Meeting Schedules. ..............................5.2.3 PMPCB Responsibilities.. ..............................5.2.4 Responsibilities of the Program PMPCB

Contractor ..........................................

5.3 MANAGEMENT OF PMP SELECTION. ............................

5.3.1 Parts, Materials, and Processes Selection List (PMPSL)5.3.2 PMPSL Records .............................,...........5.3.3 Part (Material or Process) Approval Request (PAR).....5.3.4 As–designed Parts and Materials List ..................

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5.4 MANAGEMENT OF PMP ENGINEERING REQUIREMENTS .............. 20

5.4.1 System Designs ........................................ 205.4.2’ Registered PAP. ....................................... 205.4.3 Reuse of Parts and Materials. ......................... 215.4.4 PMP”Qualification. .................................... 215.4.4.1 General ............................................. 215.4,4.2 Qualification by Extension. ......................... 225.4.5 Incoming Inspection Requirements ...................... 235.4.5.1 Incoming Inspection of Electronic Parts ............. 235.4.5.2 Incoming Inspection Of Materials .................... 245.4.6 Configuration Control ................................. 245.4.7 Failure Analysis ...................................... 245.4.8 Traceability and Lot Control .......................... 245.4.9 Shelf–life Control .................................... 255.4.10 Preservation and Packaging. .......................... 255.4.11 Handling and Storage.. ............................... 255.4.12 Defective Parts and Components Control Program ....... 26

● 5.5 MANAGKllENT OF PARTS AND MATERIAL PROCUREMENT ............ 26—

5.5.1 Electronic Parts Procurement Order of Precedence ...... 275.5.2 Coordinated Procurement. .............................. 275.5.3 Electronic Parts Manufacturer Surveillance (Monitoring)275.5.4 Manufacturing Baseline. ............................... 275.5.5 JAN Class S Operating Stock Program ................... 27

5.6 MANAGEMENT OF PARTS AND MATERIALS APPLICATION ........... 28

5.6.1 Derating .............................................. 285.6.2 PMP Application Data.. ................................ 28

5.7 RADIATION HARDNESS ...................................... 29

6. NOTES .................................................... 31

6.1 INTENDED USE ............................................ 31

6.1.1 Related Statement of Work Requirements ................ 326.1.2 Related Equipment Specification Requirements .......... 32

6.2 TAILORED APPLICATION. ................................... 33

6.3 TAILORING TO CONTRACT PHASE. ............................ 34

a 6.4 DATA ITEM DESCRIPTION. .................................. 34

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6.5

6.6

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CONTRACTOR PROPOSAL ..................................... 36

MPCAG FUNCTIONS ......................................... 36

JAN CLASS S OPERATING STOCK ............................. 37

SUBJECT TERM (KEYWORD) LISTING ......................... 37

APPENDICES

A. RETESTING OF ELECTRONIC PARTS ........................... 39

B. HARDNESS ASSURANCE ...................................... 45

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MIL-STD-1546A (USAF)01 IL%R’1988

SECTION 1

SCOPE

1.1 PURPOSE

This standard establishes the requirements for thepreparation, implementation, and operation of a parts,materials, and processes control program for use during thedesign, development, advanced development, engineering

. development, production, modification, and test of space andlaunch vehicles. The implementation of these requirements isintended to:

a. Assure integrated management of theselection, application, procurement,control, and standardization of parts,materials, and processes (PMP)

b. Improve the reliability of program PMP toreduce PMP failures at all levels ofassembly

c. Reduce program life cycle cost

d. Improve procurement of small quantitiesof parts that meet the system requirements

1.2 APPLICATION

This standard is intended for use in acquisition contractsfor space.vehicles, upper stage vehicles, payloads, spaceexperiments, and launch vehicles. The standard should be citedin the contract schedule or the statement of work. tailored tothe extent that may be applicable. The requirements areintended to be used to coordinate at the program level theselection, application, management, and procurement of PMPthroughout the design, development,of an acquisition.

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SECTION 2

REFERENCED DOCUMENTS

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2.1 GOVERNMENT DOCUMENTS

Unless otherwise specified, the following specifications,standards, and handbooks of the issue listed in that issue ofthe Department of Defense Index of Specifications and Standards(DoDISS) specified in the solicitation form a Part of thisstandard t~ the

SPECIFICATIONS :

MIL–C-123

MIL–S–19500

MIL–M-3851O

STANDARDS:

extent specified herein.

Capacitors, Fixed, Ceramic Dielectric,(Temperature Stable and General Purpose),High Reliability, General Specification for

Semiconductor Devices, General Specificationfor

Microcircuits, General Specification for

MIL-STD–1547 Electronic Parts, Materials, and ProcessesTechnical Requirements for Space and LaunchVehicles

HANDBOOKS:

MIL-HDBK-339 Custom Large Scale Integrated CircuitDevelopment and Acquisition for Space Vehicles

(Copies of specifications, standards, handbooks, drawin9s, and;ubiications- required by contractors in connection with~pecified acquisition f~nctions should be obtained from thecontracting activity or as directed by the contracting officer.)

2.2 ORDER OF PRECEDENCE

In the event qf a conflict between the text of this standardand the references cited herein, the text of this standard shalltake precedence. Nothing in this standard, however, shallsupersede applicable laws and regulations.

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SECTION 3

DEFINITIONS AND ACRONYMS

3.1 DEFINITIONS

3.1.1 Acquisition Activity. The acquisition activityis the Government office or agency acquiring the equipment,system, or subsystem for which this standard is beingcontractually applied.

3.1.2 Cateaories of contractor. The term “contractor”signifies a producer of modules or higher level items ofequipment. A contractor that provide items to anothercontractor can be identified as a “subcontractor”. Somesystem programa have one major contractor identified as a“prime contractor”, who is responsible directly to theacquisition activity. Other programs may have two or moremajor contractors, each responsible directly to theacquisition activity (neither one subordinate to the other),which are called “associate contractors”. In the case ofprograms with associate contractors, the acquisition activitymay designate one associate contractor as responsible formanaging tbe program Parts, Materials, and Proceaaes ControlProgram. In this standard, when the term contractor is used,it applies to the prime, the associate, or the subcontractor,whichever is applicable.

3.1.3 c~ . A contracting officer is aperson with the authority to enter into, administer, orterminate contracts and make related determinations andfindings. .The term includes authorized repreaentatives of thecontracting officer acting within the limits of theirauthority as delegated by the contracting officer.

3.1.4 Electronic Parts. The’term “electronic” is usedin a broad sense in this standard and includes electrical,electromagnetic, electromechanical, and electro–optical.These parts are associated with electronic assemblies such ascomputers, communications equipment, electrical power,guidance, instrumentation, and space vehicles. Electronicparts also include connectors.

3.1.5 JAN Class s Part. A JAN Class S part is anelectronic part that is buiIt, tested, qualified, and procuredin full accordance with the space quality level requirementsas specified in its general and detailed militaryspecification.

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3.1.6 Manufacturing Baseline. The manufacturingbaseline is a description, normally in the form of a flowchart, of the sequence of manufacturing operations necessaryto produce a specific item, part, or material. Themanufacturing baseline includes all associated documentationthat is identified or referenced, such as:”that pertaining tothe procurement and receiving inspection, storage, andinventory control of parts and materials used; themanufacturing processes; the manufacturing facilities,tooling, and test equipment; the in–process manufacturingcontrols; the operator training and certification; and theinspection and other quality assurance provisions imposed.Each document is identified by title, number, date of issue,applicable revision, and date of revision.

3.1.7 Material. Material is a metallic or nonmetallicelement, alloy, mixture, or compound used in a manufacturingoperation which becomes either a temporary or permanentportion of the manufactured item.

3.1.8 Material Lot. A lot for material refers tomaterial produced as a single batch or in a single continuousoperation or production cycle and offered for acceptance atany one time.

3.1.9 Military Parts Control Advisorv Group OIPCAG) .The MPCAG is a Department of Defense organization whichprovides advice to the military departments and militarycontractors on the selection of parts in assigned commodityclasses, and collects data on nonstandard parts for developingor updating military specifications and standards.

3.1.10 Off–the-shelf Item. An off-the-shelf item is anitem which has been developed and produced to military orcommercial standards and specifications, is readily availablefor delivery from an industrial source, and may be acquiredwithout change to satisfy a military requirement.

3.1.11 m. A part is one piece, or two or more piecesjoined together, which are not normally subjected to disassemblywithout destruction or impairment of its designed use.

3.1.12 Parts. Materials. an~ Processes Control Board~PMPCB ~. The PMPCB is a formal organization established bycontract to assist the contractor and acquisition activity”inmanaging and controlling the selection, application,procurement, and documentation of parts, materials, andprocesses used in equipment, systems, or subsystems.

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3.1.13 ar sP t , t . d Processes c EMa eriala an Sele tion Lis(PMPSL1 . The PMPSL is a list of all parts, materials, andprocesses which are approved for design in a specific contract.

3.1.14 Process. A process is an operation, treatment, orprocedure used during a step in the manufacture of a material,part, or an assembly.

3.1.14 Production Lot (Electronic Partsl. A productionlot of electronic parta refers to a group of parts of a singlepart type; defined by a single design and part number; producedin a single production run by means of the same productionprocesses, the same tools and machinery, and the samemanufacturing and quality controls; and tested within the sameperiod of time. All parts in the same lot have the same lotdate code.

3.1.15 Registered PMP. A registered PMP is a Part,material, or process which is registered with the acquisitionactivity to call attention to special reliability, quality, orother concerns, relating to its procurement or application.Registered PMP includes, but is not limited to, reliabilitysuspect PMP and limited application PMP.

e3.1.16 sDac Oualitv PMP Baseline. The Space Quality PMP

Baseline definesethe parts, materials, and processes which arerecommended and approved by the acquisition activity for designselection, application, and procurement for a specificcontract. For electronic piece parts this would normallyinclude all space level military qualified products, such asMIL–M-3851o microcircuits, Class S; MIL-S–19500 semiconductors,JAN S; and MIL-C-123A ceramic capacitors. For mechanical partsthis would normally include parts meeting the contractualrequirements. The Space Quality PMP Baseline should bespecified in the solicitation.

3.2 ACRONYMS

3.2.1 MPCAG

3.2.2 P&J!

3.2.3 E!ME

3.2.4 PMPCB

3.2.5 E&IL?S&

Military Parts Control Advisory Group(See 3.1.8)

Part (or Material or Process) Approval Request(Data Item Description, DI-MISC-80071)

Parts, Materials, and Processes

Parts, Materials, and Processes Control Board

Parts, Materials, and Processes Selection List(Data Item Description, DI-MISC-80072)

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MIL–sTD-1546A (USAF)01 MAR 1988


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MIL-STD–1546A (USAF)01 MAR 1988

SECTION 4

GENERAL REQUIREMENTS

4.1 PARTS MA IAL. TER S. AND PROCESSES CONTROL PROGRAM PLANN ~IN

The contractor shall establish and conduct a parts,materials, and processes control program in accordance with therequirements of this standard. This parts, materials, andprocesses control program shall be documented in a plan (DataItem Description, DI–MISC-80526) that addresses how therequirements of this standard are to be met. When therequirements of this standard are imposed on a contractor, it isintended that all of their appropriate subcontractors would alsoparticipate in the parts, materials, and processes controlprogram to the extent that they are required in order to meetthe objectives of this standard. The plan shall address how thecontractor ensures the flow down of the applicable p“arts,materials, and processes control program requirements to thesubcontractors.

●4.2 PARTS. MATERIALS . AND PROCESSES CONTROL BOARD (P14PCB}

A Parts, Materials, and Processes Control Board (PMPCB)shall be implemented by the contractor who is identified andtasked by the acquisition activity to plan, manage, andcoordinate at the program level, the selection, application, andprocurement requirements of all PMP. All contractors shallsupport the PMPCB and shall implement the findings and decisionsof the PMPCB to the extent that the contractors are covered intheir contractual effort. The acquisition activity shall havethe right .of disapproval of PMPCB decisions.

4.3 MANAGEMENT OF PK4PSELECTION

The contractor shall manage the selection of PMP inaccordance with tbe criteria specified in this standard. Thecontractor shall develop a Parts, Materials, and ProcessesSelection List (PMPSL) (Data Item Description, DI-MISC–80072) tobe used by all contractors on the program for their design andmanufacture. PMP included in the Space Quality PMP Baselineprovided by the acquisition activity shall be consideredapproved for use if included in the PMPSL. PMP not included inthe Space Quality PMP Baseline provided by the acquisitionactivity which is proposed to be included in the PMPSL shall besubmitted to the PMPCB for coordination and subsequent approvalby the acquisition activity using the Parts Approval Request

●(PAR) (Data Item Description, DI-MISC-80071). Deletions or

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MIL–STD–1546A (uSAF)01 MAR 1988

other Changes to the PMPSL shall be coordinated through thePMPCB . For electronic parts, when the Space Qaality PMPBaseline parts are not available, the applicable requirements ofMIL-STD–1547 shall be applied in selecting and procuring partsand materials to meet space quality requirements.

4.4 MANAGEMENT OF PMP ENGINEERING REQUIREMENTS

PMP shall be selected to meet the requirements of the systemapplication; however, design preference shall be given to tbeselection of applicable PMP listed on the Space Qual”ity PMPBaseline until superseded by the approved PMPSL. PMPengineering requirements shall be managed by the PMPCBaccordance with the requirements of this standard.

4.5 MANAGEMENT OF PARTS AND MATERIALS PROCUREMENT

in

When applicable and appropriate, the contractor shall ensurethe use of coordinated procurement to obtain parts and materialsfor contractor and subcontractor use. Contractors areencouraged to use the JAN Class S Operating Stock to procureparts to the maximum extent possible. Justification by thecontractor or subcontractor for the nonuse of parts which areavailable from the JAN Class S Operating Stock is required bythe PMPCB. The selection of suppliers for other parts andmaterials shall be based on criteria that includes factors toensure the required quality and reliability can be procured.The contractor shall ensure that source surveillance for allparts and materials is provided to assure the quality of partsand materials. JAN Class S parts do not require contractorsource surveillance to meet the requirements of this standard.

4.6 MANAGEMENT OF PARTS. MATERIALS. AND PROCESSES APPLICATION

The contractor shall ensure proper application of all parts,materials, and processes. Tbe contractor shall also ensure thateach application of parts is derated to meet system requirements.

4.7 RADIATION HARDNESS ASSURANCE

As necessary, the contractor shall plan for and implementhardness assurance requirements for materials and electronicparts to meet system requirements in accordance with Appendix B.

4.8 COMPLIANCE WITH SYSTEM REQUIREMENTS

The requirements of this standard shall not relieve thecontractor-of the responsibility for complyingequipment, system performance, and reliabilityset forth in the applicable specifications and

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with all therequirementscontracts.

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4.9 GOVERNMENT FURNISHED EOUIPMSNT

PMP contained in unmodified government furnished equipmentused in the end item of the contract shall not be subject to PMPcontrol procedures by the contractor. When required bycontract, the “as built”’PMP list shall be reviewed to theextent possible by the PMPCB to identify possible problem areas,or areas where substandard parts are being used. Problems aswell as substandard parts shall be presented and identified tothe acquisition activity.

The contractor shall implement the PMP selection,application, and procurement provisions described herein for PMPto be used for any modification of government furnishedequipment intended for use in the end item of the contract.

4.10 OFF–THE-SHELF ITEM (EOUIPMENTl

Parts and materials contained in off–the–shelf equipmentused in a space or launch vehicle shall meet the part andmaterial selection, application, procurement, and approvalprocedures described herein. When off–the–shelf equipment cannot be supplied that satisfies these requirements, the equipmentshall not be used in a space or launch vehicle without specific

● approval of the contracting officer.

4.11 CUSTOM LARGE SCALE INTEGRATED CIRCUITS

The guidance provided by MIL-HDBK–339 shall be the basis forthe procurement of custom large scale integrated circuits. Eachcustom large scale integrated circuit planned for system usageshall be selected, developed, analyzed, and tested in accordancewith the guidance provided by MIL–HDBK-339. The monitoring,auditing, hardness assurance, and testability guidance ofMIL-HDBK-339 shall be followed.

4.12 VERY HIGH SPEED INTEGRATED CIRCUITS

Very high speed integrated circuit technology shall beselected for use where applicable and where its use does notdegrade system reliability. The acquisition and technicalguidance provided by MIL-HDBK-339 is directly applicable to veryhigh speed integrated circuit devices and should be followedwhen identifying requirements and uses of this technology forspace and launch vehicle systems.

4.13 USAF SPACE DIVISION SPACE PARTS WORKING GROUP

The contractor is encouraged to provide representation to

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MIL-sTD-1546A (USAF)01 MAR 1988

●These meetings are usually held periodically (approximatelyannually) at or near.the USAF Space Division. The purpose ofthese meetings is to provide a forum for the exchange ofinformation relating to technical, procurement, application, andstatus issues of interest involving space programs andespecially space quality parts. The primary focus is on generalparts issues or items including their selection and procurement.

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MIL–5TD-1546A (uSAF)01 MAR 1988

SECTION 5

DETAILED REQUIREMENTS

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5.1 PARTS. MATERIALS. AND PROCESSES coNTROL PROGRAM PLANNING

5.1.1 Pa t M teria s an~.The parts, materials, and processes control program shall bedocumented in a plan (Data Item Description, DI-MISC-80526)prepared by the contractor identified and tasked by theacquisition activity to plan, manage, and coordinate the programlevel PMPCB. The plan shall be comprehensive and shall describehow the contractors effort is to be organized, managed, andconducted to meet the requirements of this standard. Individualtopics or subordinate plans may be prepared as separate documentsand incorporated by reference into the overall parts, materials,and processes control program plan. Existing contractornonproprietary in–house documentation may be used and referencedin the plan when applicable. Contractor documents referenced inthe plan shall be made available to program participants uponrequest. The parts, materials, and processes COntrOl pr09ram

●plan shall include the following major topics:

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b.

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d.

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f.

9.

A PMPCB operating procedure, including membership,responsibilities, authority, meeting schedules, PMPreview procedures, PMP approval procedures, andplans for updating the operating procedure.

The role and authority of each PMPCB member has insupport of PMPCB meetings, in preparing PMPdocumentation, and in providing timely informationon P14Pproblems to the PMPCB.

Definition of the contents of the PMPSL andprocedures for developing, updating, approving, anddistributing the PMPSL.

Procedures for identifying “registered PMP.”

Initial milestone schedule depicting significantPMP events (e.g., completion dates for PMPSL andother planning documents).

Development and implementation of a shelf lifecontrol plan (see Appendix A).

Development and implementation of application andderating documents to meet program derating policy(e.g., MIL-STD-1547 for electronic parts).

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MIL-sm-1546A (U5AF)01 MAR 1988

Development and implementation of Dlans andproced~res for man~facturer and subcontractorsurveillance and auditing.

Development and implementation of plans andprocedures for qualification and qualificationupdating.

Development and implementation of policies andprocedures to ensure that design engineers selectPMP described by the Space Quality PMP Baselineto the maximum extent practicable.

Development and implementation of plans andprocedures for coordinated procurement, whereapplicable.

Development and implementation of plans andprocedures for conducting destructive physicalanalysis of parts at incoming inspection, andrelated review and approval procedures.

Development and implementation of a DefectiveParts & Components Control Program.

●Development and implementation of methods for theprogram integration of PMP requirements,reliability requirements, and quality controlefforts. Include methods for coordinationbetween the PMPCB, Failure Review Board, MaterialReview Board, and other applicable boards orgroups.

Development of the definition of the authority ofthe PMPCB as it relates to various groups withinthe Prime, associate, and subcontractororganizations.

Development and implementation of a RadiationHardness Assurance Program and Plan, ifapplicable.

Development and implementation of plans andprocedures to meet electrostatic dischargeprotection requirements for PNP.

Development and implementation of plans andprocedures for contamination control of criticalsurfaces of parts and materials duringmanufacturing, shipping, and handling.

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MIL-STD–1546A (U5AF)01 MAR 1988

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s. Implementation of plans and procedures for usingthe Defense Electronics Supply Center (DESC) JANClass S Operating Stock Program for theprocurement of JAN Class S parts.

5.1.2 Milestone Schedule. A milestone schedule shallbe developed showing the interrelationship of program relatedPMP activities to the program schedule, including completiondates for the PllPSLand other planning documents. Thismilestone schedule shall be presented to and maintained by thePMPCB to assist in identifying and resolving problems.Milestones at each subcontractor shall be identified. Amethod shall be developed for closed loop task control andreporting to program management and to the acquisitionactivity on a regular basis.

5.2 PARTS. MATERIALS. AND PROCESSES CONTROL BOARD (PMPCB)

5.2.1 Membership. The PMPCB membership shall includeat least one member from each contractor and each appropriatesubcontractor. The acquisition activity shall be representedby an active member on the PMPCB and shall retain the right ofdisapproval of PMPCB decisions. Each member shall be capableof being supported in technical matters as required. Eachmember shall have the authority to commit his organization orcompany to PMPCB decisions which are within the scope of hiscontract and consistent with the parts, materials, andprocesses control program plan.

5.2.2 PMPCB Meetina Schedules. PMPCB meetings shall beheld as follows:

a. A post–award PMPCB organizational meeting shallbe convened by the contractor designated theprogram PMPCB manager within 30 days aftercontract award. The chairman of the PMPCB shallcoordinate the date and location of the meetingwith the acquisition activity, and informproposed members and representative of theschedule. This meeting is intended to establishinitial working relationships, responsibilities,and procedures for implementation of the PMPcontrol program. This meeting may be held inconjunction with other scheduled contract reviewmeetings.

b. Subsequent PMPCB meetings shall normally be heldmonthly, or as suitable to the program activitylevel.

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c. Special PMPCB meetings may be called by thePMPCB chairman or the acquisition activity, asrequired, with adequate notification provided toall the PMPCB members and representatives (7calendar days minimum notification).

5.2.3 PMPCB Responsibilities.

a.

b.

c.

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The PMPCB shall establish PMPCB operatingprocedures in accordance with this standard.

The PMPCB shall establish and maintain a programPMPSL . Each member shall coordinate theidentification and applicable data for candidatePMP proposed for the PMPSL. When required, eachmember shall request approval of items using aParts Approval Request (PAR) form with thesupporting flata, including qualification andevaluation plans. The PMPCB shall recommendapproval or disapproval to the acquisitionactivity for each PAR.

The PMPCB shall ensure selection and use of PMplisted on the Space Quality PMP Baseline to themaximum extent practicable.

The PMPCB shall identify, control, and limit theuse of registered PMP. The PMPCB shall alsoreview applicable process controls and specialcontrols to be imposed on any registered P14Pused.

The PMPCB shall ensure compliance with therequirements of this standard to the extent theyare invoked on contract. The PMPCB shallevaluate and recommend approval or disapprovalto the acquisition activity for deviations orwaivers on the requirements of this standard.

The PMPCB shall develop a uniform deratingpolicy to meet the system requirements andmonitor its use by all contractors andsubcontractors on the program. The PMPCB shallevaluate and recommend approval or disapprovalto the acquisition activity for any “exceptionsto this uniform derating policy.

The PMPCB shall develop a standardizeddestructive physical analysis policy, procedure,and reporting format and recommend their use by

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m.

all contractors and subcontractors on theprogram. The destructive physical analysis.findings and a summary report shall be reviewedby the PMPCB on a regular basis.

The PMPCB shall review the results of receivinginspection, destructive physical analyses,failure analyses, Material Review Board actions,and problems including those identified in thefield. The PMPCB shall notify the acquisitionactivity with recommended corrective actions.

The PMPCB shall ensure the timely initiation ofprocurement of long lead procurement items.

The PMPCB shall identify to the acquisitionactivity those changes required in partspecifications necessary to meet the equipment,system, or subsystem requirements.

The PMPCB shall review the selection (if used)of custom large scale integrated circuits inaccordance with the guidance from MIL-HDBK-339.

The PMPCB shall ensure the proper control of allprocesses approved for space and launch vehicleuse. This includes ensuring the properselection, application, and use of each processas well as the control of associated items whichdo not become part of the manufactured item.

The PMPCB shall review plans by programcontractors or subcontractors to procure JANClass S parts from sources other than the JANClass S Operating Stock Program when they areavailable from the Operating Stock Program.

5.2.4 ~ onsibiliti we Prou am BContractor. The contractor designated by the acquisitionactivity as responsible for the PMP Control Program shall:

a. Provide the PMPCB Chairman, conduct PMPCBmeetings, prepare and distribute meeting minutes(Data Item Description, DI-A-7089), and managethe PMPCB.

b. Prepare PMPCB meeting agenda (Data ItemDescription, DI-A-7088), distribute meetingnotices and agenda a minimum of 21 calendar daysprior to the PMPCB meeting (7 calendar daysprior for special PMPCB meetings).

17



5.3 MANAGEMENT OF PMP SELECTION

The contractor shall use the following PMP review and approvalprocedures for parts to be selected and listed on the PMPSL:

a. After contract award, those items which thecontractors and subcontractors propose to useshall be definitized in the format of a PMPSL andsubmitted to the PMPCB for review and approval,and to the acquisition activity for theirapproval. PMP not defined by the Space QualityPMP Baseline in the solicitation, and proposed forinclusion on the PMPSL shall require submission ofan approval request (PAR) with supporting data.When this list is approved by the acquisitionactivity, it becomes the approved PMPSL and shallbe used by all contractors and subcontractors onthe program when selecting PMP for program use.The PMPSL shall not be formally issued until ithas been approved by the acquisition activity.

b. Each contractor shall update the PMPSL through thePMPCB as required to support their designefforts. All PMP proposed for use, but notapproved or listed on the PMPSL, shall be clearlyidentified at all design reviews and information ●shall be presented to justify their selection anduse.

c. Following approval of any additions to ordeletions of PMP to the PMPSL, all changes to thePMPSL shall be made available to all contractorson the program in a timely manner.

5.3.1 Parts. Materials. and Processes Selection List (PMPSL).The PMPSL (Data Item Description, DI-MISC–80072) shall beorganized into three separate sections:

Section I for approved parts,Section II for approved materials, andSection 111 for approved processes.

Each PMP listing in each section of the PMPSL shall contain, asa minimum, the following information:

a. PMP index number (including revision )

b. Generic part number (manufacturer’s designation)

c. Military specification number, slash sheetnumber, and dash number, as applicable

18


MIL-sTD–1546A (u5AF)01 MAR 1988

d. Contractor PMP identification

e. Noun description

number

f. Approved, proposed, and selected sources

~. Status (such as: on-order or in-house)

h. Qualification status

i. Identification of any application limitations

i. Identification as “registered PMP” if sodesignated

k. Reference file number for the PMP application data

Each item listed in the PMPSL and identified as “limitedapplication PMP” or as ‘“registeredPMP” shall also listinformation on applicable restrictions and reasons.

5.3.2 PMPSL Records. Records of the program PMPSL shallbe organized into three separate sections similar to the PMPSL:Section I for parts, Section II for materials, and Section III

● for processes. Records shall be kept for the life of theprogram. The records shall include as a minimum the following:

a.

b.

c.

The PMPSL.

Approved PMPSL data, including registration orcritical listing, if applicable.

Proposed PMP. This is the PMP for which approvalaction is pending The records for the proposedPMP should be organized similar to the listing ofthe PMPSL (see 5.3.1).

Addition and deletion actions.

Disapproved PMP. This is the PMP that has beendisapproved for program use. Each item listed as“Disapproved PMP” shall also list information onapplicable reasons for disapproval and the dateof disapproval.

Id.

Ie.

5.3.3 Part (Material or I?rOCeSS) ADDrOVal Reauest (I%R1.A PAR (Data Item Description, DI-MISC–80071) shall be submittedto the PMPCB for all PMP not defined by the Space Quality PMPBaseline and proposed for listing on the PMPSL.

@

I

19


,


Supplemental data required with this request includes as aminimum the following:

a.

b.

c.

d.

e.

f.

9.

Justification for the proposed applications.

Reliability history, test data, other programusage and history, and any failure snalysisreports, relevant GIDEP Alerts, and otherrelevant Alerts.

Availability including approved, proposed, andselected sources.

Genersl performance and application data.

Description of how the technical requirements aremet; including qualification.

Any criteria which meet the requirements toregister the PMP (see 5.4.2).

Process methods and data and required qualitycontrol provisions, if applicable.

5.3.4 As–desianed Parts and Mate rials List. As theprogram progresses, the PMPCB shall be responsible for thedevelopment and maintenance of an as-designed parts andmaterials list which shall indicate the final parts andmaterials selected, quantities used, next assembly location,and end item location. Parts and materials approved orqualified for program use, but not actually used, shall not beincluded on this as-designed list.

5.4 MANAGEMENT OF PMP ENGINEERING REQUIREMENTS

5.4.1 System Desians. The PMP shall tieselected to meetthe requirements of the system application; however, designpreference shall be given to the selection of applicable PMPdescribed by the Space Quality PMP Baseline. The contractorshall limit the number of different PMP used by selecting PMPfor new design from the existing PMPSL approved by theacquisition activity. PMP not described by the Space QualityPMP Baseline shall meet the requirements of the contract.Electronic parts shall meet the requirements of MIL-STD–1547.

5.4.2 Registered PMP. The PMPCB shall identify to theacquisition activity any proposed use of registered PMP.Registered PMP are PMP which meet any of the following criteria:

a. Requires special handling, transportation,storage, or test precautions. a“

20


MIL–sTD-1546A (uSAF)01 MAR 1988

b.

c.

d.

e.

f.

9.

h.

i.

j.

Unsatisfactory performance on current program orhistorical data showing unsatisfactoryperformance on other programs, including relevantGIDEP Alerts, industry problem alert bulletins,and other relevant industry problem notices oralerts.

PMP with any limitations that warrants additionalcontrols.

Parts or materials difficult to manufacture orprocesses difficult to control.

The.part or material is stressed in theaPPliCStiOn in excess of,recommended deratingcriteria.

The PMP involves any deviation from themanufacturing baseline procedure affecting systemperformance.

Limited application PMP.

The part, material, or process is,identified as areliability suspect PMP

State-of-the-art manufacturing or technology withinsufficient reliability history

PMP which represents a single point of failurefor the system

Additional controls shall be applied to registered PMP toensure their suitability for system use.

5.4.3 Reuse of Parts and Mate rials. Parts and materialswhich have been installed in an assembly, and are then removedfrom the assembly for any reason; shall not be used again inany item of flight or space hardware.

5.4.4 PMP Qualification.

5.4.4.1 General. All PMP, including any processesdeveloped to accomplish rework or retrofit, shall be qualifiedfor program use. Only qualified PMP shall be used on flighthardware. For each nonqualified PMP, the contractor(s), throughthe PMPCB, shall prepare a qualification plan and procedure.For electronic parts, the qualification plans and proceduresshall be based on the requirements of MIL–STD–1547. Thequalification plan shall identify all conditions and testing

21


MIL-sTD-1546A (U5AF)01 MAR 1988

●necessary to meet the program and mission reliability andqualification requirements. These plans and procedures shall bereviewed and approved by the PMPCB prior to acquisition activityapproval. A summary report of qualification test results shallbe submitted to the PMPCB. The PMPCB shall maintain anup–to–date listing of the qualification status’of all programPMP . Test methods used for qualification of PMP shall be inaccordance with applicable specifications and shall include testmethods for any additional tests necessary to fully qualify thepart for its intended use in the system.

Qualification of PMP may be expedited by the following:

a. Initial selection of PMP using applicable militaryspecified PMP previously qualified for use onspace and launch vehicle programs.

b. Proof testing of all parts and materials to theprogram requirement levels.

c. Vendor audits and certification.

d. Satisfactory completion of tests on engineeringmodels that use the PMP

5.4.4.2 Qualification by Extension. Parts, materials, orprocesses may be qualified by extension when either of thefollowing criteria are met:

a. The part, material, or process was successfullyused in a prior but recent space application inwhich the application environment conditions ofuse and test were at least as severe as thoserequired of the candidate PMP for qualification.

b. The part or material is of identical constructionor contains constituents identical in compositionand near identical in significant properties asthe previously qualified part or material. Thepart or material is manufactured by the samemanufacturing facility to the same manufacturingbaseline as the previously qualified part ormaterial, and the utilization of the part ormaterial does not result in critical stresses ormechanical strain (such as due to a temperature orthermal mismatch) greater than the previouslyqualified part or material.

Qualification by extension shall be based on a review ofsupporting data by the PMPCB and approval by the acquisitionactivity.

22



III

5.4.5 Incominq Inspection IZequirements. Each contractorshall perform, or be responsible for performing, applicableincoming testing and inspections to parts and materials toensure that they meet the requirements of the procurementspecifications. Parts or materials not meeting lot acceptancecriteria shall not be used on qualification or flight hardware.Unless previously accomplished and accepted by contractor fieldpersonnel, incoming testing and inspections shall beaccomplished upon receipt of the parts or materials.

5.4.5.1 Incominq Insuection of Electronic Parts. As aminimum, incoming inspection of electronic parts shall consistof the following:

a. One hundred percent external inspection at 10Xmagnification (minimum) for such things aspermanent and legible marking, body finish, leadfinish, insulation, lead straightness, excessivematerial misalignment dimensions, and any visualor mechanical defect.

b. A destructive physical analysis on a lot samplebasis in accordance with procedures approved bythe PMPCB. The minimum sample size shall be aquantity of five (5) per each lot date code. WithPMPCB approval, the contractor may use anindependent destructive physical analysispreviously performed on the same production lotdate code as evidence for the quality of the lot,in lieu of performing another destructive physicalanalysis. An example of this is shown by notrequiring another destructive physical analysisfor parts procured from the Defense ElectronicsSupply Center (DESC) JAN Class S Operating StockProgram.

c. For PMP not defined by the Space Quality PMPBaseline:

1). One hundred percent electrical testing at25 ~ 5 degrees Centigrade to detailspecification requirements.

2). Electrical testing at specified temperatureextremes on a lot sample basis.

d. Data accompanying all parts shall be reviewed todetermine acceptability of received parts andwhere possible to provide a lot–by–lot trendanalysis.

23



5.4.5.2 Incominq Inspection of Materials. As a minimum,incoming inspection of materials shall consist of the following:

a. Analysis of significant physical properties ofrandomly selected samples “of “as received”material.

b. Sample analysis of significant physical propertiesof processed material (where appropriate).

c. Review of all data accompanying the lot to ensurethat the material meets all specified requirements.

5.4.6 confiauration control. The contractor shall planfor and assess the physical characteristics of all parts andmaterials for the purpose of identifying any changes in thematerials used, construction, or configuration of the parts ormaterials. As a minimum for parts, the contractor shall usemanufacturer data and initial destructive physical analysisfindings to baseline the physical characteristics of the parts,and then to compare subsequent destructive phYsical analYsisfindings to that initial baseline.

5.4.7 Failure Analysis. Failure analysis shall beperformed on part and material failures experienced duringreceiving inspection, production, and testing. Failures shallbe analyzed to the extent necessary to understand the failuremode and cause, to detect and correct out-of-control processes,to determine the necessary corrective actions, and to determinelot disposition. A standardized trouble and failure reportingsystem and summary report format shall be established by thePMPCB and used by all contractors in the program. Correctiveaction shall be determined and implemented for each failure.All failures, and the results of failure analysis, shall bereported to the PMPCB and to the acquisition activity. Failedparts and failure analysis reports shall be retrievable for theduration of the contract, and shall be available to theacquisition activity for independent examination. Failuresattributed to processes shall be recorded and analyzed toidentify cause of failure and need for corrective action. Allsuch data and the corrective actions taken shall be submitted tothe PMPCB for review. Failure of parts procured from the DESCJAN Class S Operating Stock Program require immediatenotification to DESC, the PMPCB, and the acquisition activity.

5.4.8 Traceability and Lot Control. The contractor shallbe capable of tracing each part and each material batch procuredfor system use to its manufacturer, lot identification (lot datecode or batch designation), and serial numbers (where a serialnumber exists). Similarly, given a lot date code, the

24



●contractor shall be CaDable of determining the uniaue uiece ofequipment by serial nu~ber (and dash numb=r) at th; lo~estassembly level in which the part is installed.

5.4.9 Shelf–life Control. The contractor shall develop ashelf–life control plan to identify the inspections and testsrequired to ensure shelf life for each part type. Parts ormaterials shall be installed into equipment within four yearsfollowing receiving inspection or within four years followingrescreening or retesting in accordance with a PMPCB approvedplan. Guidance for the preparation of the shelf-life controlplan is presented in Appendix A. The shelf–life control planshall be documented and referenced in the parts, materials, andprocesses control program plan.

5.4.10 Preservation and Packaaing. Preservation,packaging, and packing shall be in accordance with both the itemand the system requirements. All parts which are subject todegradation by electrostatic discharge, and which are to bepacked in bags or wraps manufactured from static-generatingmaterials, shall first be individually wrapped in properanti–static material. The anti-static packaging material shallbe intimate to the item. An approved label shall be affixed toeach unit package clearly advising that the contents can be● destroyed by static electricity and should be handled only bypersonnel instructed in the necessary precautions.

5.4.11 ~. Handling and storageprocedures shall be instituted to prevent part and materialdegradation. These procedures shall apply until the parts andmaterials lose their individuality when assembled into modules,boards, or higher indentured items. The handling and storageprocedures shall be retained through inspection, kitting, andassembly.and shall be identified on “build to” documentation.The following criteria shall be used as a minimum forestablishing handling and storage procedures for psrts andmaterials:

s. Control of environment, such as temperature,humidity, contamination, and pressure.

b. Measures and facilities to segregate and protectparts and materials routed to different locationssuch as, to the materials review crib, or to alaboratory for inspection, or returned to themanufacturer from unaccepted shipments.

c. Easily identifiable containers to identify spacequality parts shall be used.

‘e

I

25



d.

e.

f.

~.

h.

i.

j.

5.4.12

Control measures to.limit personnel access toparts and materials during receiving inspectionand storage.

Facilities for interim storage of parts andmaterials.

Provisions for protective cushioning, as required,on storage area shelves, and in storage andtransportation containers.

Protective features of transportation equipmentdesign to make sure that packages are notaccidentally dropped or dislodged in transit.

Nondegradable cushioning of bench surfaces onwhich parts and materials are handled duringoperations such as test, assembly, inspection, andorganizing kits.

Required use of gloves, finger cots, tweezers, orother means when handling parts to protect theparts from contact by bare hands.

Provisions for protection of parts susceptible todamage by electrostatic discharge. ●

Defective Parts and components control Proarsm.The PMPCB shall review and evaluate Government Industry DataExchange Program Alerts (GIDEP ALERTS), industry problem alertbulletins, and other available information relating to defectivePMP to ensure that defective PMP are not selected for the designor procured for use, or used in system equipment. PMP indicatedas defective in any GIDEP ALERT, industry problem alertbulletins, industry problem notices or alerts, or other sourcesof problem information shall not be approved for use or listedon the PMPSL unless the indicated defects or failures have beencorrected or identified, and approved preventions implemented toeliminate the cause of the defects or failures in the parts tobe used in the flight hardware.

5.5 MANAGEMENT OF PARTS AND MATERIAL PROCUREMENT

All parts and materials shall be procured directly from themanufacturer or procured from an authorized distributor. Partsand materials procured from an authorized distributor shall betraceable to the manufacturer and a written certification by lotdate code of specification compliance, shall be furnished by themanufacturer with each procurement. Contractors are encouragedto use the JAN Class S Operating Stock Program to procure partsto the maximum extent possible.

9

26



5.5.1 Electronic Parts Procurement Order of Precedence.The contractor shall procure JAN’Class S parts aa the firstorder of precedence. For parts not on an applicable spacequality military qualified products list (QPL), the contractoris encouraged to place orders with manufacturers willing topursue qualification during the processing of the order so thatthe delivered product can be space qualified. When JAN Class Sparts and other space qualified military standard parts andmaterials are not obtainable, the contractor shall procure partsand materials in accordance with the technical requirements ofthe system and of the contract. For any PMP not specificallycovered by contractual requirementa, the contractor, with PMPCBapproval, shall select and apply specification and testrequirements appropriate to the specific part or material type,design, and manufacturing process. Space quality testprocedures and requirements shall be used.

5.5.2 Coordinat ed Procurement. The contractor shall usecoordinated procurement practices wherever possible. Thisincludes the use of common specifications, common managementresponsibilities, common purchaae agreements, common monitoring,and common quality aasurance responsibilities by severalcontractors. A contractor may develop a master purchaseagreement, where applicable, which allows individual contractors

● to initiate their own procurements within the scope andframework of the master purchase agreement.

5.5.3 Electronic Parts Manufacturer Surveillance-to rinrQ. The contractor shall arrange for thesurveillance of all nonJAN Class S procurements of electronicparta at the manufacturer. For all nonJAN Class S electronicparts the contractor shall participate in precap visualinspections and shall monitor the screening and qualityconformance tests performed by the part manufacturer. Thecontractor shall be responsible for authorizing shipment of theelectronic parta from the manufacturer.

5.5.4 Manufactu rina Baseline. All nonJAN Class S partsand all materials shall be procured to a manufacturing baselinefor the parts or materials which has been approved by thecontractor.

5.5.5 JAN Class s OPeratina Stnck Proaram A JAN Class SOperating Stock haa been initiated by the Defense LogisticsAgency to allow contractors to procure JAN Class S parts thatare readily available from stock. This reduces procurement leadtimes, and allows small quantity ordering. In support of thisprogram, the contractor shall:

a. Forecast requirements for using stock listed parts.

27



b. Submit requisitions for stock listed parts throughthe contracting officer.

c. Obtain approval from the !?MPCB for plans to buy’Stock listed JAN Class S parts from sources other “than the Defense Electronics Supply Center (DESC),when they are available at DESC.

5.6 MANAGEMENT OF-PARTS AND MATERIALS APPLICATION

5.6.1 Derating. A uniform derating policy to meet thesystem requirements shall be established by the PMPCB and usedby all contractors in the program. Exceptions to this deratingpolicy shall require the approval of the PMPCB. The deratingpolicy shall address degradation sensitive parameters andmaximum rated variations expected over the program mission life.The policy shall also include derating due to radiation effects.

5.6.2 PMP Applica tion Data. Each contractor shalldevelop, and have on file, application data for each item on thePMPSL that they are using or are proposing to use. The PMPapplication data shall be consistent with program requirementsand shall be readily available to all circuit and equipmentdesign engineers. The application data shall, as a minimum,contain the following:

a. Configuration drawing,.

b. Recommended mounting procedure.

c. “Recommended derating

d. Common failure modes :

e. Estimated failure rate

f. Environmental capability (e.g., shock or vibrationlimitations or outgassing)

9. Expected degradation due to radiation and aging.

h. Identification of registered items and reasons forbeing registered

The contractor shall identify all critical areas in eachcomponent and subsystem. A stress analysis shall be performedfor each part or material employed in each criticalapplicatio~. These analyses shall relate the stress of parts ormaterials to circuits, module, components, and subsystemperformance as they are influenced by parametric variations,

28


MIL-sTD-1546A (uSAF)O1:MAR 1988

‘9

environmental effects, radiation effects, and input and outputlimits. These analyses shall consider all derating factorsidentified in the approved derating criteria to determine theworst-case part stress. These analyses shall be available forPMPCB and acquisition activity review.

5.7 ~IATION HARDNESS

When required, the contractor, through the PMPCB, shalldevelop and conduct a hardness assurance program in accordancewith Appendix B for all hardness critical parts and material tomeet the hardness .asSurance regui;rement,sof the SYStem. Thehardness assurance program plan shall address all phases of theflight hardware program including the design, test, andproduction. The hardness assurance program shall ensure:

a. Radiation environments for piece parts andmaterials are specified.

b. Hardness assurance requirements and appropriatetest methods are identified and included in therespective procurement specifications.

c. Hardness assurance representatives support thePMPCB

The hardness assurance program plan shall be documented andreferenced in the Parts, Materials, and Processes ControlProgram Plan. The hardness assurance program plan shall beprovided to the PMPCB for review and to the acquisition activityfor approval prior to the Preliminary Design Review.

29




30

il



SECTION 6

NOTES

IIIIII

;

I

The contents of this section are noncompliantand are intended for guidance and information only.

6.1 INTENDED USE

This standard should be cited in the contract schedule, orthe statement of work, to specify the requirements for theparts, materials, and processes management and control programfor applicable equipment. The standard is intended for use inall USAF Space Division acquisition contracts for new ormodified designs of space vehicles, upper stage vehicles,payloads, launch vehicles,, and for their subtier equipments.Note that this standard is not an appropriate reference in anyspecification since it is a management standard and does notcontain technical requirements for the parts, materials, andprocesses to be used in the equipment. Of course, allrequirements for data delivery must be listed in the Contract

● Data Requirements List of the acquisition contract.

The requirements in the text of this standard expand theapplicable Parts Control Program requirements as stated inMIL–STD-965 in order to satisfy space and launch vehicleacquisition requirements. This standard also extends therequirements for part controls to also apply to materials andprocesses. For the convenience of everyone using thisstandard, and also using either MIL-STD–965 or’MIL–STD-1547,the definition of key terms that are common are the same inthis standard as in those documents.

Contracts for ground equipment (e.g., control segments anduser segments of space systems) could apply MIL-STD-965 forthose segments unless it is determined that a tailoredapplication of this standard wouldbe more appropriate for thereliability or standardization objectives of the program.Note that many space and launch vehicle acquisition contractsinclude both space and ground equipment, so if bothMIL-STD–965 and this standard are referenced, care should betaken to ensure that the applicability of each document isclear.

There may be acquisition contracts for other types ofequipment requiring high reliability where the special parts,materials, and processes control requirements stated in this

●III

!,

31


i.iIL-STD-1546A(USAF)01 WAR’ 1988

standard should be applied. For ’thos’eacquisition contracts,this standard may be cited to specify the applicablerequirements. However, a statement should be included in thecontract or the statement of work indicating that the words“’spaceand launch vehicle” in this standard are to beinterpreted as the applicable equipment. The requirements inthis standard should therefore Reinterpreted asapplying tothe parts, materials,. and processes control programrequirements for the acquisition of the applicable equipment.The specific wording in the statement of work or in thecontract could avoid any possible misinterpretation ormisapplication.

6.1.1 Related Statement of Work Requirements. Thisstandard cannot achieve’”a successful program standing alone.There is an implied assumption that other critical managementrequirements will be implemented. Other criticat managementrequirementsinclude, but

a.

b.

c.

d.

to be implemented in the statementof workare not limited to, requirements. for:

Quality program (MIL-STD-1586, MIL-STD-1535,’ andMIL-Q-9858)

Reliability program (MII.I-STD-1543)

Nonconforming material reviews (MIL-STD–1520)

Program reviews ’’(MIL-STD–l52l)

6.1.2 Related Eauipment SDedification Reauirements.This standard cannot achieve a successful program standingalone. There ‘is an implied assumption that critical technicalrequirements will be implemented. Critical technical ‘requirements to be implemented in the equipment specificationsinclude, but are not limited to:

a. Technical requirements forlaunch vehicles (JAN CLASSMIL-STD-1547)

b. Technical requirements forand launch vehicles

c. Technical requirements forand launch vehicles

d. Technical requirements foranalysis (MIL-sTD–1580)

parts for space andS parts and

materials for space

processes for space

destructive physical

32


‘MIL-’sTD-1546A”(USAF)01 MAR”i988

a .6.2 TAILORED .APPLICATION,,

The p“aits,materials,’

,, .:,~ .,

and ‘processescontrol programrequirements “in each,contract,‘showl”dbe ‘tailored to “the needsof that particular acquisition. Military specifications “andstandards need not be ‘applied in khei~ entiret”y:“Only theminimum requirements needed to provide the basis for achievingthe PMP required should be imposed. .The. cost of’’imposing each”requirement of this standard should be evaluated by theprogramo fficeagainst the benefits that ”’shouIdbe realized.provisions (section, ‘paragraph&i “or sentences) not requiredfor the specific application Should.be excluded. Thesurviving provisions $.houl’dbe tailored to impose only theminimum requirements ‘necessary to support the system. Alltailored, applications’of this standard siiallbe clear~yidentified” in’the compliance document section of the””statementOf work of the contract.

,,

In the caseof programs with two or more associatecontractors, the acquisition activity should includein eachof the’contractor “contracts‘one of the following:

*

a. The PMP program shall comply with MIL-STD-1546.The contractor is responsible for all’requirementsincluding the Program PMPCB management tasks.Other contractors responsible for,,supporting thePMPCBare:

(Note: this statement would be for the contractoridentified as the Program PMPCB Contractor that ‘would be responsible for the’ProgramPMPCBmanagement tasks. All paragraphs of MIL–STD-1546are applicable. The other contractors responsiblef,orsupporting the PMPCB should be identified socoordination can start.)

b. The PMP program shall comply with MIL-STD-1546except for paragraphs 5.1.1, 5.1.2 and 5.2.4. Thecontractor is responsible for supporting the PMPCBorganized by , theProgram PMPCB Contractor responsible for theprogram level PMPCB management tasks.

(Note: this statement would be for contractors notdirectly responsible for the Program PMPCBmanagement tasks. The Program PMPCB Contractorresponsible for the Program PMPCB management tasksshould be identified).

33



eThe planned responsibility and interrelationship of the

PMPCB to any other PMP efforta should also be stated in eachcontract involved. In all cases, the Space Quality ET@ Baselineof approved PMP for design selection, application, .andprocurement should be specified in the solicitation, ifavailable, to simplify the contractors efforts.

6.3’ TAILORING TO CONTRACT PHASE

This standard contains a comprehensive management programthat requires reliability and standardization considerations beapplied during all phases of the program. When this standard ismade compliant in a ,contract for a concept development phase orfor a validation and demonstration phases, it does not implythat space quality technical requirements and managementprocedures apply to anything other than qualification and flighthardware (e.g. they do not apply to ground demonstrationmodels) . Contracts for the demonstration and validation phaseare encouraged to require the development of a parts, materials,and processes control program plan and at least a first draft ofthe PMPSL. The contractor should, therefore, have a completeunderstanding of the entire PMP program to successfully transitioninto subsequent phasea of the contract. The standard is intendedto be “self tailoring” in this respect.so,that specific tailoringto each phase of the contract would not:be required. ●6.4 DATA ITEM DESCRIPTION

Data requirements of this document are not to be considereddeliverable unless specifically identified as deliverable datain the contract or purchase order and the appropriate Data ItemDescription (DID) is referenced. When this standard is used inan aCqUiSitiOII which incorporates a DD”Form 1423, Contract DataRequirements List (CDRL), the data requirements identified belowshould be developed as specified by an approved Data ItemDescription (DD Form 1664) and delivered in accordance with theapproved CDRL incorporated into the contract. When theprovisions of the DoD FAR.clause on data requirements (currentlyDoD FAR Sub Part 27.475–1 are invoked and the DD Form 1423 isnot used, the data specified below should be delivered by thecontractor in accordance with the contract or purchase orderrequirements. Deliverable data required by this standard iscited in the following paragraphs:

Paragraph No. Data Requirement Title Applicable DID No.

4.1 & 5.1.1 Parts Control Program Plan DI–MISC-805264.3 & 5.3.1 Program Parts Selection List DI–MISC-800724.3 & 5.3.3 Part Approval Request DI-MISC-800715.2.4 Conference Agenda DI–A–70~85.2.4 Conference Minutes DI–A–7089 ●

34



(Data item descriptions related to this standard are listed inDoD 501O.12-L., AMSDL. Copies of data item descriptionsrequired by the contractors in connection with specificacquisition functions should be obtained from the NavalPublications and,Forms Center or as directed by the contractingofficer.)

The appropriate data item description of the Contract DataRequirement List (CDRL: DD Form 1423) shou~d contain aninstruction in Block 16 to ensure that submittals include allrequired parts, materials, and processes data. The tailoring ofthe data required by this standard is as follows:

a. Parts, Materials, and Processes Control Plan.Data Item Description, DI-MISC-80526, PartsControl Program Plan. To satisfy the requirementfor a Parts, Materials, and Processes ControlProgram Plan, tailor the DID to include materialsand processes in the scope. Tailor the DID toreference.paragraph 5.1.1 of this standard forcontents. For USAF Space Division contracts,place,SD/ALT on distribution. The preliminary.parts, materials, and processes control programplan should be provided to the PMPCB for reviewand to the acquisition activity for approvalshortly after contract award. The finalparts,materials, and processes control program shouldbe provided. to the PMPCB for review and to theacquisition activity for approval prior to thePreliminary Design Review.

b. Program.Parts, Materials, and Processes SelectionList (PMPSL). Data Item DescriptionDI-MISC-80072 Program Parts Selection List(PPSL). Tailor the DID to include materials andprocesses in the scope. Tailor the DID toreference paragraph 5.3.1 of this ‘standard forinformation required on the PMPSL. It isimportant to require that the contractor list theindustry generic number onthe PMPSL to allowindependent computer searches for suspect parts.For USAF Space Division contracts, include TheAerospace Corporation Reliability and ComponentsData Center on distribution. The initial issueof the PMPSL should be provided to the PMPCB forreview and to the acquisition activity foraPPrOval shortly after contract award and alwaysprior to the Preliminary Design Review.

I

e35


MIL-STD-15,46A,(USAF)O.l;I$AR 1988

●,,, ,,C. Additions .to the PMPSL. Data. Item Description

DI-MI,SC-80071, Part Approval Request, “isused to.. add PMP to the PMPSL: Tailorthe DID ‘toinclude

materials and processes “in the,scope~,,,., Tailor the.D~D,to reference paragraph 5;3.3 .of this.standard”for contents. ,:

d. Electronic data base. Tailor.the .CDRLi.or .applicable :DIDs to require reports and data : , ~~

!,’ generated on anelectronic database to alsobedelivered using acopyof.the data base. The” ‘, ‘delivered electronic database, media and format,.!should be as approved by the acquisition activity.

., ,-“.~,.,:., ,,. ,

6.5 CONTRACTOR PROPOSAL !.: ~~ ,.

., ~. ,., ., .,

The.contractorproposal shouldclearly,set forth the plansand procedures for implementing ,a.,costeffective ,highreliability parts:management program. .Theproposed plan shoulddefine the scope and,depth,of the contractors.efforts includinghis management approach, organization. ’staffing planning,technical. aspects, and the .relationship,.ofthe.parts program tothe contractors:other.technical andmanagement:programs. Thisshould cover.the technical and.management requirements of thestandard. Invitations for bids, request for proposals and ●contractual. statements of work, should include .requirements for:

a.

,.

,b.””

,,., ,.Compliance with the~Space Quality PMP Baseline,when furnished, to themaximumextentpracticable. .Note that on contracts forfollow-on production of existing designs, theSpace Quality PMP Baseline may be,the as-designedparts and materiala list:for,the earlierproduction, updated to account for recommendedPMP:improvements. ~,,,. .,.,, ,,,Time period for acquisition activity response tothe,proposed.PMPSL; and proposed additions to thePMP.SL :s:normally. 30..,galendar,days, although adifferent .tirnemay be:specified,to suit acontract application.. ~~ :;”

,,, ,.’Submission of ,aParts.,Materials, and ProcessControl ProgramFPlan ,. ‘, , .,

.,. ,,

6.6 MPCAG FUIiCTIONS , : ‘, ,“, .::., .. ,.

The function of theMP”CAG:i&:to.act. as an advisor to theacquisition activities and contractors in its assigned commodityclasses. The MPCAG would recommend standard parts or inventory

.36



parts that meet the design requirements of the equipment orsystem in which the part is to be used. Moreover, the MPCAGaccepts technical information about specification changesnecessary to make a specification usable, and request actionwith the military activity responsible for that specification toexpedite appropriate changes. NOTE : For a complete listing ofthe commodity classes for which the MPCAG is responsible as wellas a listing of contact points with addresses and telephonenumbers, see MIL–STD-965.

6.7 JAN CLASS s OPERATING STOCK PROGRAM

A JAN Class S Operating Stock has been initiated by theDefense Logistics Agency to allow contractors to procure JANClass S parts that are readily available from stock. Thisreduces procurement lead times, and allows small quantityordering. Standard contract clauses which authorize contractorsto use the stock should be inserted in a separate section of thecontract.

6.8 SUBJECT TERM (KET WORD) LISTING

BaselineClaas Scontrol boardJAN Class SlotpartsmaterialsMPCAGoperating stockPMPPMP baselinePMPCBPMPSLprocessesregisteredselection listspace

CustodiansAir Force - 19

Preparing ActivityAir Force - 19(Project No. 1820-FO08)Document 1275b Arch 1204b

37


MIL-sTD-1546A (USAF)01 MAR1988

●


38


I

III

I


APPENDIX A

RETESTING OF ELECTRONIC PARTS

The contents of this section are noncompliantand are intended for guidance and

10. SCOPE .

This appendix provides the retestingto meet Shelf-life Control requirements.

20. ADDED REFERENCED DOCUMRNTS

information only.

instructions necessary

MIL–STD–105

MIL-STD-202

MIL–STD–1285

Sampling Procedures and Tables forInspection by Attributes

Test Methods for Electronic andElectrical Component Parts

Marking of Electrical and ElectronicParts

30. SHELF-LIFE CONTROL.

Parts with lot date codes within four years of installationmay be installed without further action. Parts with lot datecodes older than four years of installation shall be subjectedto a pedigree review and retesting as specified by the programPMPCB prior to installation on equipment. Parts which initiallymet all program part specification requirements but have notbeen subjected to screening tests, inspections, and sample testswithin four years shall be subjected to a pedigree review andretesting as specified by the program PMPCB prior toinstallation on equipment. Parts which have had any waiver ordeviation granted to the program parts specificationrequirements shall automatically be subjected to program PMPCBreview and approval before installation regardless of age. ThePMPCB’S decision for retesting shall be based upon lot size,part quality procurement requirements, original screening data,Government Industry Data Exchange Program (GIDEP) data, otherALERTs for problems on the same part or generic family of partS,the original destructive physical analysis results, significantchanges in the part being reviewed from current produced parts,available failure history, part construction variables, themanufacturing records, storage and handling environments, andother related considerations.

A-1

II

39


MIL-5TD-1546A (U5AF)01 MAR 1988

30.1 Lot Size and Part Qua lity. The lot size and theoriginal part quality procurement requirements shall beidentified. Part quality requirements are JAN Class S QPLdevices, parts in full compliance with MIL-STD-1547, and otherdevices.

30.1.1 JAN Class S OPL Devices and MIL-STD–1547 Devices.JAN Class S QPL devices and parts in full compliance withMIL–STD–1547 shall have randomly selected samples tested asdirected by the PMPCB. The sampling schedule in Table A–1 isintended as a guide for the PMPCB. The sample size is similarto General Inspection Level III per MIL-STD-105D. The specificsample size selected should be based upon all informationgathered. The testing shall be in accordance with therequirements of Table A-2; however, additional tests or changesmay be required by the PMPCB when so indicated by informationgathered from ot,lerconsiderations. Any failures shall requireanalysis to determine screenability of the failure mechanism anddisposition by PMPCB to reject the lot or to screen 100 percent.

Table A-1 Retesting Sample Size Guide

Lot Size RetestinqSample Size

1–5051-9091-150

151-280281–500501–12001201-32003201–10,000

ALL203250’80

125200315

●

30.1.2 Other Devices All devices other than JAN Class SQPL devices, and devices ~hat are in accordance withMIL-STD-1547, shall be retested 100 percent unless the PMPCBdetermines retest is not necessary. As a minimum, the screensof Table A–2 are required. PMPCB shall assess the need foradditional screens based upon considerations in the followingparagraphs.

A–2

40


‘e

MIL-STD-1546A (U5AF)01 MAR 1988

Table A–2. Retests l/

Part TYDe Screenina Tests 2/Capacitors (all types) 1. Thermal Shock (except glass)

2. Capacitance and Dissipation Factor3. Seal (Hermetic only)

Tantalum +DC LeakageVariable +DC Leakaae, Toraue and Linearitv

Connectors NoneCrystals 1. Electrical Parameters (+25 deg C)

2. SealFilters 1. Thermal Shock

2. Seal (Hermetic only)3. Electrical Parameters (+25”C)

Fuses 1. Seal (Hermetic only)2. DC Resistance (+25”C)

Inductors, Coils 1. Thermal Shockand Transformers 2. Seal (Hermetic only)

3. Electrical Parameters (+25°C)Relays 1. Seal

2. Electrical Parameters (25”C)Resistors (all typf2S) 1. DC Resistance (+25 deg C)

Variable +Mechanical PerformanceSemiconductors and 1. SealMicrocircuits 2. Electrical Parameters (+25°C)dcSwitches 1. Contact Resistance

2. Oueratina Mechanical Performance3. SGal (He;metic onlv)

Thermistors 1. Seal (Hermetic only)2. DC Resistance (+25”C)

l/ This table reflects the minimum retesting for JAN Class SQPL devices and parts in full compliance withMIL-STD–1547 when originally procured.

2/ Tests and electrical parameters shall be as specified inthe detail specification.

30.2 Oriainal Screenina Data. Examine the originalscreening data to determine extent of rejects during screening,including the actual percent defective allowed compared to thespecified percent defective allowed (when specified). If theactual percent defective allowed was “hi9h” compared to other lotsof the same part type, 100 percent retesting should be performed.

A–3

41



30.3 GIDEP. Examine data contained in the GovernmentIndustry Data Exchange Program (GIDEP) to determine problemswhich may have occurred during qualification, evaluation, orother testing by other contractors.

30.4 ALERTS. Search ALERTs for problems on the same partor generic family of parts, which would indicate a time-relateddegradation problem or some anomaly for which tests had notpreviously been performed.

30.5 Destructive Phvsical Analysis. Perform a review ofthe original destructive physical analysis results to determineif lot was considered marginal, types of anomalies detected andif ,time-related.

30.6 PMP Control. When possible, determine from themanufacturer or other sources, any significant changes in thepart being reviewed from current produced parts which wouldindicate the parts should be retested, or have a special testperformed if the parts have a potential reliability hazard.

30.7 Usaae History. Review available failure history forpotential reliability hazards which would indicate specialtesting or retesting of the parts is required. This may includeusing history and quantity of parts used. ●

30.8 Part Construct ion. Component specialists shallsupport the PMPCB in the assessment of part constructionvariables and their impact upon time-related failuremechanisms. Some typical concerns are the need to bake-outcarbon composition resistors, moisture effects on capacitor,and aging of gold-aluminum bonds.

30.9 Part SUDD lier. Verify that the manufacturer hasbeen maintained as an approved source per QPL or contractorapproved vendor list.

30.10 Storaae Environment. Determine what theenvironments were during storage (such as temperature, relativehumidity, and transportation vibration).

30.11 Storaae Control. Determine what electrostaticdischarge, handling, packaging, bonded inventory, and similarcontrols were used.

30.12 Storaae Period. Determine what the total durationof storage at the manufacturer and the contractor has been.

A-4

42



30.13 Next Assembly Usaae. When possible, determine thecriticality of the application, the stress, the deratingparameters, and the ability of box level tests to detect latentpart failures.

40. RETESTING.

When the retests in Table A-2 are performed, the number ofrejects during the retesting plus the number of rejects duringthe original screening shall not exceed the original specifiedpercent defective allowed, when specified. When a percentdefective allowed was not a requirement for the originalscreening, the number of rejects allowed during the retestingshall be determined by the PMPCB.

50. EXTERNAL VISUAL EXAMINATION.

Following the retesting, an external visual examinationshall be conducted on all parts to determine that there are nodegradation effects due to time.

60. IDENTIFICATION OF RETESTED LOTS.

After retesting, a new lot date code shall be marked on the● partin accordance with MIL–STD-1285 that indicates the week of

the completion of the retesting. Hand printing is acceptable.The marking shall be capable of meeting the permanencyrequirements specified in MIL-STD-202, Method 215. If spacedoes not permit the marking of the new lot date code, the firstdigit of the original lot date code may be changed to the number“9’”. The original marking to be retained.

70. RETEST DATA REVIEW

A satisfactory review shall be performed of the variablesdata (recorded) between the original screening dats and theretesting data indicating no parameter degradation with time.

80. DESTRUCTIVE PHYSICAL ANALYSIS

For those parts where a destructive physical analysis hadbeen previously performed on the original lot, an additionaldestructive physical analysis may be necessary depending uponthe review results of the original destructive physical analysisdata. Attention shall be made to determine any effect on thepart due to time during the analysis.

A-5

43



90. FINAL ACCEPTANCE

Final acceptance of the parts is based upon evaluation ofthe data analysis and retesting data (when parts are retested)by the Program. Concurrence shall be obtained from the PMPCB.Lots or parts failing the retesting may be submitted to thePMPCB for consideration for usage with ample justification.

A–6

44


MIL–sTD-1546A (uSAF)01 MAR 1988

APPENDIX B

HARDNESS ASSURANCE

This Appendix is a mandatory part of the standard.

10. SCOPE .

This appendix provides the detailed requirements formanaging the radiation hardness assurance of piece parts.

20. HARDNESS ASSURANCE PROGRAM.

The contractor shall develop and implement a radiationhardness assurance program for piece parts during the design,construction, and production of the spacecraft. The hardneasassurance tasks include but are not limited to:

a.

b.

c.

d.

e.

f.

20.1 Hardness Ass urance Organization. The contractorshall identify a survivability and vulnerability organization

Formation of-an hardness assurance organization.

Development of an hardness assurance program plan.

Development,of hardness asaurance requirements.

Representation of hardness assurance issues atpreliminary design review and critical design review.

Representational PMPCB meetings and during capabilityaudits.

development of hardness assurance design documentation.

whose respons~bilities includ~ the implementation, control, andcoordination of all hardness assurance activities associatedwith piece parts. This organization shall interface with theirmanagement on hardness assurance issues and assignresponsibilities as required to ensure that all aapects of thehardness assurance Program are carried out.

20.2 Hardness Assurance Proaram Plan. The contractorshall develop and document an hardness assurance program planfor piece parts which details the hardness assurance tasks andidentifies responsibilitiea for assuring that the tasks arecarried out. This hardness assurance program plan shall.be

B–1

45


MrL–sTD-1546A (USAF)01 MAR 1988

incorporated as a section of the parts, materials, and processescontrol program plan. Applicable sections shall also beincorporated in the overall qualit’y assurance plan for pieceparts. The hardness assurance program plan shall address thefollowing items:

a.

b.

c.

d.

e.

f.

~.

h.

i.

j.

k.

1.

B-2

Description of the hardness assurance organization withdesignated responsibilities.

Responsibilities of representatives to the PMPCB, topreliminary design reviews, to critical design reviews,and to capability audits.

Definition of the system radiation environments.

Specification of worst–case radiation environments forpiece parts.

Definition of failure of piece parts in each radiationenvironment and in each critical circuit applications.

Specification of end point electrical parameters,tolerances, recovery times following a nuclear eventand parameter values at the end of mission.

Maintenance of a radiation characterization data basefor

For

1.

2.

3.

piece parts.

custom LSI:

A feasibility analysis which demonstrates that theproposed design snd technology are adequate forthe radiation requirements.

Identification of hardness assurance criticalfactors in design, layout, processing, assembly,and handling.

Identification of hardness assurance testabilityrequirements and test chips.

Verification analyses and tests.

Device categorization in each environment and in eachcritical circuit.

Preparation of

Development of

the radiation test

hardness assurance

requirements.

design documentation.

●

46


MIL-STD-1546A (U5AF)01 MAR 1988

20.3 Hardness Assurance Requirements. When militaryhardness assured parts levels M, D, R, or H per MIL–S–19500 orMIL-M-3851O are unavailable or do not meet specified radiationenvironments, the contractor shall attempt to incorporate hisradiation requirements within the framework of the existingmilitary specification system. When incompatibility of thecontractor’s requirements and the military specification systemhas been verified and approved by the acquisition activity, thecontractor may develop detailed specifications or source controldocuments (SCDS) for the piece parts. All technicalrequirements for radiation hardness shall be included in thedetailed specifications or SCD, either directly stated or byreference to other documents. These requirements shall conformto MIL-STD–1547. The requirements shall include:

a.

b.

c.

d.

e.

f.

9.

h.

Radiation test methods and test circuits.

Sample size and sampling method.

Radiation types and specification level.

Pre–and post-radiation response parameters and failurecriteria.

Required confidence level (C) and survival probability(P).

Dosimetry requirements.

Special radiation tests such as electrical or radiationscreening tests.

Categorization criteria.

In addition, the procurement paper should also indicate thelist of approved radiation test facilities, the data reportingand analysis requirements, and the failure analysisrequirements.

20.4 Hardness Assurance Desian Documentation. Thecontractor shall prepare a Hardness Assurance Design Documentwhich details all radiation analyses and test data for pieceparts. This document shall include, but not be limited to:

a. Circuit schematic, functional description, pin-out,operating conditions, and application of each criticalcircuit.

B-3

47


MIL-sTD–1546A (USAF)01 MAR 1988

b.

c.

d.

e.

f.

9.

h.

i.

Specification of worst case radiation environment forpiece parts in each critical circuit.

The list of piece parts for each critical circuitshoying the radiation design margin between worst casecircuit requirements and the degradation of piece partsdue to radiation.

Part categorization in each critical circuit and eachenvironment.

Results of hardness verification analyses and tests.

Testability requirements and description of hardnessassurance test chips.

List of critical design and processing parameters ineach radiation environment.

Lot acceptance criteria and test results.

Special controls screening and testing specified forCategory 1 piece parts.

20.6 Preliminary and Critics 1 Desian Reviews. Thecontractor shall have an hardness assurance representativepresent at the preliminary and-critical design reviews. ‘Thecontractor shall ensure that all system design decisions thataffect hardness assurance of piece parts are made with theconcurrence of the hardness assurance representative. Inaddition, the representative shall ensure that the hardnessassurance program plan, the Hardness Assurance Design Document,and the detailed specification are appropriately modified, ifnecessary, to incorporate any hardness assurance criticaldecisions made at the preliminary and critical design reviews.

30. HARDNESS ASSURANCE FOR CUSTOM LARGE SCALE INTEGRATEDCIRCUITS (L51C).

Additional requirements for custom LSI devices are detailedin MIL–HDBK–339.

The hardness assurance organization shall ensure that thefollowing tasks are included during the design and constructionof custom LSIC.

●

a. Designer and manufacturer capability audits.

B-4

48



b. Feasibility assessment performed by the contractorduring conceptual design phase.

c. Design requirements for hardness assurancetestability. This may include testable network, testchips and special probe and bond pads.

d. Radiation critical layout rules and circuit designconsiderations.

e. Critical procedures and processes requirements duringwafer fabrication and assembly.

40.0 HARDNESS ASSURANCE VERIFICATION

40.1 Hardness Verifica tion Analvses. The contractor shallperform and document radiation analyses of the critical circuitsto ensure that the piece parts used in the circuit are capableof meeting the hardness assurance requirements.

40.2 Radiation Characte rization Tests. The contractorshall conduct radiation characterization of parts in thespecified radiation environments. The radiationcharacterization tests may be waived if existing data bases are

~ approved bythe parts, materials, processes control board(PMPCB) or by the procuring activity. The radiationcharacterization tests shall consist of exposing the test sampleto increasing radiation levels until the parameter or thefunctional failure value for the device has been reached. Thesefailure values shall be based on a worst case circuit analysis.

50. PROCUREMENT OF PIECE PARTS.

Procurement of piece parts shall be per MIL-M-3851O, Class Sand MIL–S–19500, JAN S levels M, D, R, or H. Characterizationand lot acceptance testing for total dose and neutrons arewaived when the above hardness assured parts are selected.Testing requirements for other radiation environments shall bespecified in the detailed specification. For other parts, thecontractor shall select a wafer lot or, if unavailable, aproduction lot for all radiation testing except for total dose.Because of the large variation in total dose response that maybe observed between wafers, the contractor shall procure andsample test parts from the same wafer. The procurement shall befrom manufacturers who maintain a baseline control on the designproduction and quality control of the piece parts. Any changesin the baseline which may degrade the parts hardness shall beapproved by the acquisition activity prior to implementation.

B–5

49


[email protected]&ationd ~rnen~~t@r.~e~DP~fid=~fo~for~incubmittlns’comnumkandsuggestionsforimprovements.Allusemofmilitarystandardization documents are invited to provide

Q?

estiom. l%ii form maY be detached, folded along-theIinea indicated, taped along tbe lome’edge (D ONOTSTAJZE),and

led. In block 6, be &ssp&ific aspmsible about particular problem mauch M wording whlcb required interpretation, w-’

toorigid, rdrlctiva,loow, ambitiouc, or wasincompatible, andgiveprop.xed wording changes which would alleviate the

poblemw Enter in block 6 any mm.wks not related to aspecitlc paragraph of the document. Ifblack 7 u fried out, m

acknowledgement WW be mailed to you within 80 days tn let you know that your commenti were -eived and are being

conddered.

NOTS: TM form may not be used tG request copie8 of documents, nor to mquwt waivers, deviatiom, or clarification of

specification requirement on current contracts. Comments mbmitted on tbh fmm do not constitute or imply authorization

to waim any portion of the referenced document(s) or to amend contractual requirement.

* “.3,—.m RmnlllC+IM2t*SI-SSO*791J*W

*

(Fold dow thh he)

(Fold abnz thh Un8)

OFFICIAL EUSINE~PENALTY FOR PRIVATE USE S3W

111111! BUSINESS REPLY MAIL !1FI RS7 CLASS PERMIT NO. ,,llb WASH DC I

POSTAGE WILL BE PAID OY Ha U.S. AIR FORCE

NO POSTAGENECESSA13VIF MAILED

IN THEUNITED STATES

USAF Space Division, SD/ALMP.O. BOX 92960Worldway Postal CenterLos Angeles, CA 90009-2960


STANDARDIZATIONDOCUMENTIMPROVEMENTPROPOSAL(See[n.structions- ReserseSide)

DOCUMENT NUMSER Z.00CUMENTTITLE Parts, Materials, and Processes ControlMIL-STD-1546A (USAF)

Programfor Space and Launch Vehicles

. NAME OF SUB MITTINQOF4GANIZATION 4, TYPE0F ORGANIZATION (M.rkow)

❑ VENDOR

❑ USER

ADDRESS (Slrwt. City, S1OM,ZIP COW

❑ MANUI=AC,”BER

❑ OT”ER,SP,C,,Y,,

PROBLEM AREAS

a P.r.or.ph N.mbw .nd Wordlnw

b. ROCC.IWTIOITdOdWordin~,

c. Ro~n/R.d.Jnalo for Ro.xmwnondtiien,

REMARKS

,. NAMS OF SUBMITTER (Lat. Fi,, t. M1)-06tin.l b. WORK TELEPHONE NUMBER iI..1.&AW.Code) - Optional

MAILING ADDRESS (Sovet, City, Stole. ZIP C&) -Option.l 8, DATE OF SUB MISS1ON (YYMMDDJ

-m ----- . .A -

Uu 8%%.14zb PREVIOUS EDITION IS OBSOLETE,

. ..

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