DLAR 4125.1--PRODUCTION TESTING OF DSA-MANAGED
DLAR 4125.1
AR 70-29
NAVSUPINST 4454.2
AFR 74-12
MCO 4855.3
AQPL
DSA REGULATION
27 MAY 69
NO. 4125.1
A. DSAR 4140.34/AR 32-5/NAVSUPINST 4410.41A/MCO P10120/31A, Introduction of New Clothing and Textile Items Into Department of Defense Supply System.
B. DSAR 4235.3/AR 31-22/NAVSUPINST 4442.10/AFR 145-22/MCO 10110.24, Programming of New or Improved Subsistence Items Requiring Special Funding Into the Military Supply System.
C. DSAR 4140.50/AR 40-56/NAVSUPINST 4440.119,
Introduction of New Type Classified Medical Items Into the Department of
Defense Supply System.
D. ASPR Section XIV, Part 5, 14-502.
To
delineate policy and procedures for production testing by the Defense Supply
Centers (DSCs) of items assigned to DSA for management.
This
regulation is applicable to HQ DSA, DSCs, Defense Contract Administration
Services Regions (DCASRs), Army, Navy, Air Force, and Marine Corps. It has been
coordinated with and concurred in by the Military Services.
A. Policy
1.
Production testing of clothing, textile and subsistence, and medical materiel
items, as set forth in references I A, B, and C, will be accomplished for
specifications of new items and revision of specifications for DSA- managed
items which have undergone major changes in materials, technical requirements,
sequence of manufacturing operations, and inspection procedures in accordance
with criteria in this regulation. Production testing of new or revised
specifications for all other DSA-managed items will be accomplished upon the
request of a Military Service or the Defense Medical Materiel Board (DMMB), and
concurrence of the Commander of the cognizant DSC.
2. When
the item to be procured on a production test contract is intended for issue,
the DSC will finance the production test under the Defense Stock Fund. Other
incidental expense incurred by a DSC incident to production test will be
charged as an operating cost of the DSA procurement program, within locally
available funds. Provisions for funding of any production test contracts on
items which cannot be considered Defense Stock Fund items is the responsibility
of the Developing Service.
3.
Production tests will be scheduled sufficiently in advance so as to allow for
resolving normal production difficulties and/or production failures.
Coordination between the Developing Service and the DSC will be utilized in
production test scheduling.
4. In the event
of disagreements between a Military Service anda DSC concerning the necessity
for a production test, the Commander of the DSC will forward the comments of
the Military Service and the recommendations of the DSC to HQ DSA, ATTN:
DSAH-PR. The Chief, DSAH-PR will coordinate as necessary with the appropriate
Military Service levels to resolve differences. Unresolved differences at DSA -
Military Service level will be referred by the Director, DSA complete with
Military Service proposals and DSA recommendations, to Assistant Secretary of
Defense (I&L) for review and final decision.
B. Definitions.
1.
Developing Service. The Military Service assigned research, development, and
engineering responsibilities for the specification item. As used in this
regulation, the DMMB acts as the Developing Service for medical material items.
2. Minimum
Quality. The quantity of the specification item which represents the smallest
economic production run required to assure an adequate production test.
3.
Production Test. Testing, under contract, the adequacy and practicability of
specifications for a new or modified item to assure that the specifications
will permit quantity or mass production of quality items within economical
production practices, and that the specifications are not restrictive to
competition. (These tests usually are conducted prior to large scale
procurement of a new item.)
4.
Specification(s). Includes purchase descriptions as used in this regulation.
A. The Developing Military Service or Designated Agent will:
1. Provide
the cognizant DSC with forecasts of the recommended annual program of
production tests.
2. Prepare
the new or revised specifications, drawings, patterns, and other procurement
data.
3.
Coordinate information pertinent to the new or revised specification(s) with
the cognizant DSC during development or prior to official transmittal to the
DSC for production test.
4. Submit
recommendations and supporting facts to the cognizant DSC in those cases where
the Developing Service considers that production testing for the specification
item is not required.
5. Forward
to the Commander of the DSC, upon acceptance by the DSC of the proposed
specification(s) for production testing, copies of the specification(s) with a
cover sheet containing the following information:
a. Suggestions on number of production test contracts, if known, necessary to assure participation by representative segments of the industry (i.e., large and small business).
b. Suggestions on minimum quantities, if known, for each contract necessary to assure adequate production testing.
c. Suggested list of contractors, if known, capable of producing the item.
d. Estimated production unit cost for the suggested production test quantities.
e. A listing of the minimum production or test equipment required to produce and test the item in accordance with the specification. For new or special types of equipment, including molds, dies, tooling fixtures, not in widespread use by the appropriate industry segment, the approximate delivery leadtime for the equipment should be estimated.
f. Identification of any known long leadtime or short supply materials or components necessary in the production of the item.
g. Recommendations regarding critical and desired in-process production control points or procedures considered important to achieving production quality levels appropriate to the nature of use and cost of the item.
h. A resume of "state of the art" precautions which were highlighed during the development process and particularly during the production of experimental quantities to which the contractor(s) must give particular attention.
j. A proposed work statement for the production test contracts which will delineate any potential problem areas that may be encountered in the production of the item.
k. Submit a certification that the Research and Engineering Phase has been completed and that the specification is ready for production tests.
6. Provide
technical assistance to the cognizant DSC, and in conjunction with the DSC to
the DCASR during the period of production test and postproduction test
conferences. In addition to other assistance, technical representatives of the
Developing Service will accompany, as required, representatives of the DSC
together with those from DCASR or the acitvity performing inspection
responsibilities on visits to plants encountering serious difficulties during
the production tests, as necessary.
7. Advise
the Commander, DSC of the number of copies of final overall report of
production test on each specification that is required.
B. The Commanders of the DSCs will:
1. Review
each new specification and/or major revision to determine the need for
production tests. Where recommendations are received to omit production test of
a new or revised specification, an internal DSC review of the need for
production test will be accomplished by procurement and production, quality
assurance and technical personnel prior to a final decision to omit production
test. Where production testing is deemed necessary, but where the specification
is considered inadequate for production test purposes, the specification
changes should be resolved promptly between the DSC and the Developing Service.
2. Provide
special management attention and assign a project officer to monitor the test.
The project officer, as required, will hold and chair interim and
postproduction conferences on production test(s); prepare final overall report
of production test; and distribute reports as required by paragraph VII.
3. Fund
and conduct production test(s) as required.
4. Hold an
informal interim production test conference after the first product has been
produced and additional informal conferences as deemed necessary by the
Developing Military Service and/or the DSC. As required, hold a postproduction
test conference to review the final results of the overall production test
effort on each new or revised specification to resolve any differences among
the DSCs, the Developing Service and Defense Contract Administration Services
Office (DCASO) or the activity performing inspection regarding the need for
revision or improvement of the specification, and to coordinate technical and
production preaward survey guidance and inspection requirements developed as a
result of the production tests.
C.
The Commanders, DCASRs and/or the Military Veterinary Service will:
1. Provide
spcial management attention to production test contracts by assigning an
appropriate specialist/engineer to coordinate staff guidance, surveillance, and
technical guidance. Production and Quality Assurance specialists and/or
engineers, plus Quality Assurance Representatives (QARs) who are commodity
oriented, will be utilized in production tests. Reference I D outlines
responsibilities for veterinary service in regard to contract administration
functions for subsistence commodities. In addition to verifying the
contractor's in-process production controls and inspection procedures and
assuming normal quality assurance responsibilities, representative(s) will review
and comment on the contractor's report of the production test effort. Comments
will be in writing, cover each area of the contractor's report, and be promptly
directed to the DSC project officer responsible for the particular production
test program.
2.
Participate in postaward conferences to ensure that the production test
contractor(s) fully understands all requirements of the contract, particularly
those unique to the production test contract.
3. Ensure
that there is commonality of procedures for the administration and inspection
on concurrent contracts for production tests of a particular item.
4. Utilize
quality assurance experience gained during each production test contract to
identify and subsequently inform QARs and/or veterinarians on the peculiar
quality problems which should be given special attention during subsequent
production contracts.
D. HQ DSA
1. The
Chief, Production, Quality and Reliability Division, Executive Directorate,
Procurement and Production (DSAH-PRS), is responsible for:
a. Staffing of any production test(s) actions requiring HQ DSA resolution with appropriate HQ DSA principal staff elements or higher authority.
b. Maintaining this DSAR in a current status and review it annually.
2. The
Chief, Engineering Programs Division, Executive Directorate, Technical and
Logistics Services (DSAH-SER) is responsible for staffing any technical data
package (specification) actions requiring HQ DSA resolution with appropriate
Military Service elements.
A. During the course of a production test contract, the Developing Service and the DSC will jointly determine whether or not the proposed specification should be amended.
1. Request
for waivers to materials or technical requirements or reclassification of
defects will be forwarded to the Developing Service through the cognizant
procurement contracting officer giving full details. Where possible, resolution
of requested waivers will be accomplished at contractor's plant by
representatives of the Developing Service, the cognizant, DSC, DCASO, and/or
the inspection activity.
2. In the
event difficulty is experienced by a contractor in performing in accordance
with the proposed specification(s), the Commander, DSC will relay the
difficulty to the Developing Service. Joint action employing cross
fertilization as necessary will be taken by Government personnel to assist the
contractor(s) in overcoming the difficulty after taking cognizance of the
methods of the other successful production test contractors.
B. Specific procedures for the Procurement and Production Directorate and the Technical Operations Directorate at the DSCs are attached as Enclosure 1.
The
Commander of the cognizant DSC will provide to HQ DSA, ATTN: DSAH-PRS and
DSAH-SER each, one copy of the Annual Production Test Program; solicitation for
production tests of an item; and final overall report of the production test on
each specification. Copies, as requested, of the final overall report of the
production test(s) on pertinent specifications will be forwarded to the
Developing Service
BY ORDER
OF THE DIRECTOR, DEFENSE SUPPLY AGENCY
D. M.
SCOTT, JR.
Colonel,
USA
Executive
OFFICIAL
S. A.
MacKENZIE Colonel, USA Staff Director, Administration
1
Enclosure Specific Procedures for Defense Supply Centers
DISTRIBUTION
Army: To be distributed in accordance with DA Form 12-9 requirements for AR,
Research and Development ACTIVE ARMY: D (QUAN RQR BLOCK NO. 161) ARNG: NONE
USAR: D (QUAN RQR BLOCK 161) Navy: SNDL A4A (10 copies); A5 (BUMED only)(4
copies); FH4 (2 copies); FKA1 (less NAVSUP)(6 copies); FKM9 (2 copies); FKM14
(3 copies) FKM17 (4 copies); FKM19 (DIRNAVPUBPRINTSERVO(CL), Washington, D.C.
only); FKM21 (6 copies); NAVSUP (SUP 0821 (10 copies); 0621; 0832A (12 copies);
063; 046); Stocked: Supply and Fiscal Department (Code 514.32) Naval Station
Washington, D.C. 20390 Air Force: X: PDOs: 4000
(MC)-----------------------------------200
4002
(SJA)----------------------------------
2
4006 (AU
Lib)------------------------------- 2
4014 (IG
Lib)------------------------------- 2
4015
(SCMM)---------------------------------200
ACIC
(ACAP), 2d & Arsenal Sts, St Louis MO 63118--- 2
DISTRIBUTION
(continued) Marine Corps: MARCORPS LIST 46 plus 3700-05 (1) 6900 (2) 7000-144
(15)
Encl 1
DSAR
4125.1
AR 79-29
NAVSUPINST
4454.2
AFR 74-12
MCO 4855.3
I. The
Director, Procurement and Production Directorate, for Those New and Revised
Specification Items to be Production Tested, will:
A. Conduct an industry survey of firms capable of mass producing the item.
B. Determine contract quantities required for an economic production run.
C. Solicit proposals from firms capable of mass
producing the item. Consideration will be given to the probable benefits of
additionally employing the Directorate of Manufacturing, Defense Personnel
Support Center as one of the production test contractors in items for which it
is qualified.
D. Evaluate proposals and select contractors.
E. Award a minimum of three production test contracts, insofar as practicable, so as to assure participation by a representative segment of the industry which will be expected to ultimately produce the item in quantity. Special consideration will be given to including both large and small contractors. Priority in making awards will be given to assuring adequate representation of the industry segment, capability and willingness of the firms to accomplish the special requirements of production test contracts, and costs.
F. Contractually require the production test contractor to:
1. Provide
a planned schedule of major milestones of the production test effort and notify
the contracting officer of any major deviations from the schedule. Copies of this
schedule will be provided to representatives of the Developing Service, the
DSC, and the cognizant inspection office for the purpose of scheduling visits
to witness critical production processes.
2. Notify
promptly the contracting officer of any difficulties encountered during the
production test effort.
3. Furnish
samples from the pilot lot if required by the Developing Services.
4. Deliver
a report with required samples on the first items, a report 30-60 days later,
and then a final report within 15 days after completion of the production test
effort to the monitor. This report will contain the contractor's comments
covering difficulties encountered during the production test and his
recommendations on:
a. Recommended changes to the specification(s); including changes in requirements that will permit the use of simplified or improved mass production processes.
b. In-process and end item quality assurance of quality control requirements.
c. Production equipment required to mass product the item.
d. Required skill levels of production and inspection personnel.
e. Similar or more detailed information appropriate to the nature of the item and the specification(s).
G. Ensure that restrictive production elements are eliminated from the specification(s) by:
1.
Checking the working drawing(s) and/or specifications(s) for step-by-step
sequencing of in-process manufacturing operations. Ensure that workflow on
production line from fabrication to assembly has continuity and efficiency.
2.
Evaluating and determining requirements for special production equipment.
3.
Reviewing bill of materials for adequacy of supply.
4.
Identifying the type of skills with special emphasis on those jobs requiring
special training.
5.
Preparing report of the production aspects of the test results and participate
in the postproduction conference.
II. The
Director, Technical Operations Directorate, for Those New and Revised
Specification(s) Items to be Production Tested, will:
A. Review and coordinate proposed or revised specification(s) to assist in determining the need for production testing.
B. Review working drawing(s) and/or specification(s) for accuracy and completeness of the technical data package.
C. Review and analyze procedures considered
important to achieving production quality levels appropriate to the nature of
use and cost of the item.
D. Utilize quality assurance experience gained during the test to identify quality level checkpoints and to verify acceptable quality levels.
E. Evaluate requests for waivers and coordinate with the Developing Service.
F. Relay difficulties experienced by contractors to the Developing Service for assistance when required.
G. Participate in production tests by furnishing engineering and quality support. Provide liaison with the specification preparing activities as necessary. Participate in the postaward production test conference, and prepare a report on the technical and quality aspects of the test results.
H. Identify specification(s) requirements which may offer Cost Reduction potential.