QUALITY PROGRAM REQUIREMENTS FOR SPACE AND LAUNCH … · QUALITY PROGRAM REQUIREMENTS FOR SPACE AND...

...!1

NOT MEASUREMENT SENSITIVE

~;:.e~TD- 1586A (USAF)

SUPERSEDINGMII..XSTD-1586(USAF)Dated19JUN 87

MILITARY STANDARD

QUALITY PROGRAM REQUIREMENTS

FOR

SPACE AND LAUNCH VEHICLES

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● AMSC F4739 AREA QCIC

DISTRIBUTION STATEMENT A: Approvedforpublicrelease;distributionunlimited,

MIL-STD-1586A (UsAF)15 JUN 89

DEPARTMENT OF THE AIR FORCEWashington, D.C. 20360

MIL-sTD-1586A (USAF)

Quality Program Requirements for Space and Launch Vehicles

1. This military standard is approved for use within 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 in improving thisdocument should be addressed to:

USAF Space Systems Divisioc, SSD/CZATP. O. BOX 92960Worldway Postal CenterLos Angeles, CA 90009-2960

9by 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-1586A (USAF)15 JUN 89

.,

FOREWORD

The high reliability required of all space and launchvehicles is achieved by the designs, including the designmargins, and by the manufacturing screens and controls imposedat every level of fabrication, assembly, and test. The designand design margins should assure that the equipment is capableof performing in the operational environment, and that allsoftware functions properly. The manufacturing screens andprocess controls imposed are intended to assure that a knownacceptable product is manufactured to meet the designrequirements, and that any changes that may be required can bemade based on a known product baseline. High risks may resultfrcm inadequate designs, manufacturing processes, testing,handling, or storage provisions at any level of assembly. Forthese reasons, attention to every detail is required bycognizant personnel involved in the development, manufacture,qualification, acceptance, storage, transportation, andpreflight testing toand launch vehicles.standard is intendeddetail is achieved.that have been foundprograms.

ensure successful operation of the spaceThe quality program imposed by this

to ensure that the required attention toThe requirements are a composite of thoseto be cost effective on previous space

This standard provides a consistent approach to achieve, ina cost effective way, the high quality required for space andlaunch vehicles. The standard complements the requirements ofMIL-Q-9858 and provides supplemental requirements necessary toestablish a basis for the high quality required. Therefore, theplanning and implementation of the quality program for space andlaunch vehicles would be in accordance with both therequirements of MIL–Q-9858 and the additional requirements ofthis standard. Nevertheless, the cost of imposing eachrequirement should be evaluated against the benefits that couldbe realized. Guidance for tailoring is contained in Section 6.

Contractors are encouraged to report to the contractingofficer, for program office review and consideration, thosespecific requirements that seem inappropriate, are believedexcessive, or are conflicting with other contract requirements.However, contractors are reminded that any departure fromcontractually imposed requirements can be granted only by thecontracting officer.

For the convenience of the user of this standard, thesubsection titles in this standard are the same as thecorresponding subsections titles in MIL–Q–9858, wherever thatwas feasible. A cross reference matrix is included in Section 6relating the paragraphs in this standard to correspondingparagraphs in MIL-Q-9858 that they supplement.

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MIL-STD–1586A (USAF)15 JUN 89

CONTENT%

1.

1.1

1.2

2.

2.1

2.2

3.

4.

●4.1

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

4.2

4.2.1

4.2.2

4.2.3

PAGE

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

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

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

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

GOVERNMENT DOCUMENTS. ................................ 3

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

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

GENERAL REQUIREMENTS. ................................. 7

GENERAL REQUIREMENTS FOR THE QUALITY PROGRAM ......... 7

Quality Program Plans.. ............................ 7

Policies and Procedures ............................ 7

Management Reviews.. ............................... 7

Quality Audits ..................................... 7

Quality Program at Field Locations ................. 8

Software Quality Program. .......................... 8 IQUALITY PROGRAM MANAGEMENT. .......................... 9

Organization ....................................... 9

Responsibility ..................................... 9

Initial Quality Planning ........................... 9

4.2.3.1 Skill Requirements. ............................... 104.2.3.2 Training .........................................1o4.2.3.3 Certification Of Personnel ........................ 104.2.3.4 Recertification ................................... 10

●4.2.3.5 Records ........................................... 10

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MIL-sTD-1586A (USAF)15 JUN 89

CONTENTS (Continued)

PAGE

4.2.4 Work Instructions.. ................................ 10

4.2.4.1 Manufacturing and Test Planning ................... 104.2.4.2

4.2.4.2”.14.2.4.2.2

4.2.5

4.2.5.14.2.5.2

4.2.5.2.14.2.5.2.24.2.5.2.34.2.5.2.44.2.5.2.5

Workmanship ......................................

Standards .......................................Visual Aids .....................................

Records ...........................................

Analysis of Records.. ............................Completed Records. ...............................

Identification and Traceability .................Recording and Retrieval .........................Component Level Data Packages ...................Vehicle Level Da”taPackages .....................Data Package Review. ............................

4.3.

4.3.1

4.3.2

4.3.3

4.3.4

4.3.4.14.3.4.2

4.4.

4.4.1

4.4”.1.14.4.1.24.4.1.3

4.4.2

4.5.

FACILITIES AND STANDARDS. ..........................

Drawings, Documents, and Changes ..................

Design Reviews ....................................

Measuring and Testing Equipment ..................

Production Tooling Used as a Media of Inspection.

Records............... ............................Intervals .............................................

CONTROL OF’PURCHASES.. ...............................

Responsibility .....................................

Source Inspection .................................Group I Source Inspection ........................Intracontractor Work Authorization ................

Purchasing Data ....................................

MANUFACTURING CONTROLS ..............................

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MIL-sTD-1586A (U5AF)15 JUN 89

CONTENTS (Continued)

PAGE

4.5.1 Production Processing and Fabrication ..............

4.5.1.1 Certification .....................................4.5.1.2 Cleanliness, Contamination, and Corrosion Control.4.5.1.3 Control of Physical Environment ...................4.5.1.4 Critical Item Quality Control Requirements........4.5.1.5 Electrostatic Discharge Control Program ..........4.5.1.6 Nondestructive Evaluation .........................4.5.1.7 Critical Item Verification. .......................

4.5.2 Completed Item Inspection and Test .................

4.5.3 Statistical Process Control ........................

4.6 NONCONFORMING MATERIAL CONTROL .......................

4.6.1 Responsibility .....................................

4.6.2 Nonconforming Material Disposition .................

4.6.3 Other Dispositions.. ...............................

4.6.4 Cost of Quality ....................................

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

6. NOTES ..................................................

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

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

6.3 DATA ITEM DESCRIPTION. ...............................

6.4 SUBJECT TERM (KEYWORD) LISTING .......................

6.5 CROSS REFERENCE MATRIX TO MIL-Q-9858 ..................

6.6 CHANGES FROM THE PREVIOUS ISSUE .......................

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24

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24

28 ITABLES

TABLE I CROSS REFERENCE MATRIX TO MIL-Q-9858 ................ 25

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SECTION 1

SCOPE

1.1 PURPOSE

The purpose of this standard is to specify special qualityprogram requirements to meet the high standards necessary forspace and launch vehicles.

1.2 APPLICATION

This standard is intended primarily for use in acquisitioncontracts for selected space vehicles, upper stage vehicles,payloads, and launch vehicles. The standard should be cited inthe contract schedule, the general provisions, or the statementof work as may be applicable to specify the quality programrequirements for the acquisition. Guidance on Governmenttailoring of this Standard for specific acquisitions iscontained in Section 6.

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knL-sTD-1586A (USAF)15 CHIN89


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SECTION 2

REFERENCED DOCUMENTS

The following documents, and the documents referenced in thecited documents (first tier), form a part of this standard tothe extent specified herein. All others are for guidance andinformation only.

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 to the extent specified herein.

SPECIFICATIONS :

MIL–Q–9858 Quality Program Requirements

STANDARDS:

MIL-STD-1520 Corrective Action and Disposition System forNonconforming Material

MIL-STD-1535 Supplier Quality Assurance Program

MIL–STD-1543 Reliability Program Requirements for Spaceand Missile Systems

DOD-STD–2168 Defense System Software Quality Program

MIL–STD–45662 Calibration Systems Requirements

(Copies of specifications, standards, handbooks, drawings, andpublications required by contractors in connection withspecified acquisition functions should be obtained from thecontracting activity or as directed by the contracting officer.)

2.2 ORDER OF PRECEDENCE

In the event of a conflict between the text of this ‘standardand the references cited herein, the text of this standard shalltake precedence. However, nothing in this standard shallsupersede applicable laws and regulations unless a specificexemption has been obtained.

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MIL-sTD-1586A (USAF)15 SUN 89

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MIL-sTD-1586A (uSAF)15 JUN 89

SECTION 3

DEFINITIONS

The definitions in the referenced documents shall apply tothis standard.

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SECTION 4

GENERAL REQUIREMENTS

4.1 GENERAL REQUIREMENTS FOR THE OUALITY PROGRAM

The quality program for space and launch vehicles shall be inaccordance with the requirements of MIL–Q-9858 and this standard.Therefore, the planning and implementation of the quality programfor space and launch vehicles shall be in accordance with both therequirements of MIL–Q–9858 and the additional requirements of thisstandard. Normally, for ground equipment or other nc]nflightelements of an acquisition, only the requirements of MIL-Q-9858would be imposed by this standard. For the convenience of theuser of this standard, the subsection titles in this standard arethe same as the corresponding subsections titles in MIL–Q-9858,wherever that was feasible. A cross reference matrix is includedin Section 6 relating the paragraphs in this standard with thecorresponding paragraphs in MIL–Q–9858 that they supplement.

4.1.1 Quality Proqram Plans. The contractor shall describein a Quality Program Plan (Data Item Description, DI-QCIC-80369A)the approach for managing and implementing the qualityrequiret,.entsof the program. The contractor shall also describein a Software Quality Program Plan (Data Item DescriptionDI-QCIC-80572) the approach for managing and implementing thesoftware quality requirements.

4.1.2 Policies and Procedures. The implementation of thequality program shall be in accordance with written policies andprocedures . To assure completeness, a requirements matrix for thequality program shall be prepared which cross-references eachparagraph of this standard and of MIL-Q-9858 to the qualityrequirement paragraphs in the policy or procedure documents. Thecontractor policies, procedures, and quality program requirementsmatrix shall be available for review, upon request, by thecontracting agency or designated representative.

4.1.3 Management Reviews. Project quality management shallestablish and schedule regular reviews for upper projectmanagement on the status of the project quality program, includingaudit results, trend data, problem status, scrap/rework/repairstatus and costs and quality status for in-plant, intracontractoroperations, subcontractors, and major suppliers.

4.1.4 Oualitv Audits . The contractor shall schedule andconduct audits of personnel, procedures, and operations whichimplement the quality program. The contractor shall pay specialattention to critical subcontracts, and to critical component

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suppliers and vendors. This should include optimum use ofno-notice audits. Each audit shall be performed by contractorpersonnel familiar with written procedures and standards applicableto the operation or work. areas being audited, and shall includepersonnel not having specific line responsibilities in these areas.Each audit shall include examination of selected operations anddocumentation; evaluation of actual operations as compared withestablished requirements; recommendations, as appropriate, forremedial and preventive action; and follow-up to assess results ofaction taken. Audit shall include examination of articles,materials, and products to verify the effectiveness of thecontractor’s effort and product conformance to technical andcontractual requirements.

a. The audit schedule shall be reviewed and updatedannually to assure that optimum consideration isafforded to all areas. The frequency of auditsshall be based on criteria derived from the analysisof previous audit results. Audit frequencies may beincreased as necessary to assure that the integrityof product quality is maintained. Audit frequenciesmay be reduced when there are positive results ofcompliance to procedural and product requirements.

b. The results of audits in each area shall bedocumented in a report to contractor highermanagement with appropriate recommendations forcorrection of deficiencies. Management action shallbe taken to ensure effective correction of thereported deficiencies.

4.1.5 f)ualitv Proaram at Field Locations. The contractorquality program at field locations shall be guided by writtenpolicies and procedures. The responsibility and authority of thecontractor quality assurance representatives shall be clearlydefined. Controls over work performed at field locations shall beplanned and executed with the same level of discipline as workperformed in–plant. Policies and procedures shall emanate from orbe approved by the parent quality assurance organization. Thefield quality manager shall only be responsible to fieldsupervision for administrative matters. Technical supervisionshall be provided by the parent quality organization.

4.1.6 Software Oualitv Proqram. For deliverable computersoftware the contractor’s computer software quality program shallcomply with DOD–STD-216S.. For contractor developed nondeliverablecomputer software used to manufacture or test deliverable hardwareor software, the contractor shall implement a disciplinedmanagement system for the validation and maintenance of suchnondeliverable software, The software quality program shall bemanaged as a part of, and be consistent with, the generalrequirements for the overall quality program.

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● 4.2. QUALITY PROGRAM


MANAGEMENT

4.2.1 Organization. The contractor shall make functionalassignments to implement each element of the quality program.Personnel performing quality program functions shall havewell–defined responsibility and authority. Personnel performingquality program shall also have the organizational freedom toassess problems and to recommend and effect solutions. Thecontractor shall designate one individual responsible fordirecting and managing the quality function. This quality managershall report regularly to higher management on the status andadequacy of the overall quality program.

4.2.2 Responsibility. The contractor shall document theassignment of management responsibility and authority for eachtask of the quality program. Documentation shall include:

a. Organization charts depicting managerial levels,lines of communications, and personnel assignments.

b. Identification of the level of management havingauthority to review the status of the overallquality program and for assuring the adequacy ofcorrective actions including those betweendepartments and projects.

c. Narrative statements describing the responsibilityof each element of the contractor’s organization(e.g., procurement, engineering, reliability,fabrication, test, safety, and quality assurance)which implement the quality program.

d. The approach to quality management and surveillanceof subcontractors and major suppliers.

4.2.3 Initial Ouality Planninq. Contractor methodology forreview of the contract quality assurance tasks and identificationof needed quality resources shall be documented in writtenprocedures. Procedures shall describe quality information flowfrom contract administration personnel to those personnel assignedresponsibility for performing contract tasks and requirementsincluded in quality assurance procedures and documentation.Procedures shall also describe methods used for the review anddissemination of quality information contained in contract changes.

4.2.3.1 Skill Requirements. During initial qualitYplanning, the contractor shall identify and provide for thephysical requirements and skills needed to accomplish criticalprocessing and manufacturing operations. Requirements fOrmanufacturing and inspection personnel shall include the levels ofvisual acuity and color perception needed to perform operationalfunctions.

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4.2.3.2 Traininq. The contractor shall maintain a trainingprogram to provide adequate skill levels, including formal andon-the-job training. There shall be sufficient formal training toensure proficiency of persons performing complex or criticaloperations. The training program shall include indoctrinationregarding reliability and quality requirements of the product.Use of motivational techniques is encouraged to develop personnelcommitment toward goals of error–free superior workmanship,including the positive implications and impact on missionperformance and the enhancement of productivity.

4.2.3.3 Certification of Personnel. Contractor personnelperforming complex or critical operations, and processes requiringa high degcee of skill, shall be certified. Certification shallbe based upon objective criteria which include work experience,training, and testing. Certified personnel shall be providedevidence of certification, which shall specify the period ofeffectivity.

4.2.3.4 Recertification. When certification expires,personnel shall be recertified by testing, or review of objectiveevidence of continued satisfactory performance. The contractorshall also recertify each individual whenever significant changesare made in processes, techniques, or skill parameters, or whenphysical relocation or interruption of the work period wouldresult in degradation of quality. Whenever inspections, tests, or oquality audits identify that individual manufacturing orinspection personnel need additional training, they shall beremoved from the operation until provided with additionaltraining, and the required proficiency has been demonstrated.

4.2.3.5 Records. The contractor shall maintain records ofthe trainina, testina, and certification status of Dersonnel. Therecords sha~l be ava~iable for review by government”representatives upon request.

4.2.4 Work Instructions

4.2.4.1 Manufacturing and Test Planninq. The contractorshall have manufacturing, inspection, and test instructions forall segments of the manufacturing cycle, which shall include flowcharts or other effective alternative methods of identifying allinspection and test points. The contractor’s quality assuranceorganization shall participate in the planning and shall reviewand approve the instructions prior to release. Instructions shalinclude or reference engineering requirements, such as drawings,material specifications, process specifications, and workmanshipstandards, to assure that necessary tests and inspections areeffectively performed to verifv that the Product meets technicalrequiremenis~ Test instructio~s shall id~ntify the characteristics

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● to be measured, the methods of measurement, and the point at whichthe test is to be performed. The contractor shall address thefollowing in developing the required manufacturing inspection andtest instructions.

a.

b.

c.

d.

e.

f.

9.

h.

i.

j.

k.

4.2.4.2

Sequence of all manufacturing, inspection and testpoints to assure continuity and effectiveness of alloperations .

Inspection and test performance at the optimum itemindenture level to minimize repair or rework athigher indenture levels.

Sufficient module level environmental testing andburn-in.

Cleanliness/contamination control.

The adequacy of in–house handling and packaging,including provisions for protection of electrostaticdischarge sensitive items.

Availability and utilization of applicable standards.

Clearly defined acceptance or rejection criteria foreach inspection or test.

Special attention to monitor and document criticalitems and their characteristics.

Visual aids for inspection and assembly personnel.

Appropriate selection, application, use, and controlof substances, chemicals, shop aids, clothing, andexpendable materials specified and used in themanufacture.ng process (cleaning materials,adhesives, joining material, solvents, rags, andetc.).

Tooling, jigs, fixtures and other fabricationequipment to be utilized.

Workmanship. The contractor shall develop methodsto assure that the workmanship is adequate and meets contractualrequirements.

4.2.4.2.1 Standards. The contractor shall establishworkmanship standards. These standards can be part of designspecifications, drawings, work instructions or other readily

●available specifications and standards. The criteria in the

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0workmanship standards shall comply with contractual requirements.All standards shall define specific detailed acceptance orrejection criteria.

4.2.4.2.2 Visual Aids. When visual aids are used tosupport manufacturing or inspections, the contractor shallidentify, maintain, and control the samples, graphics, or visu~,laids that show acceptable workmanship to ensure continuedusability and proper configuration.

4.2.5 Records. The contractor shall maintain a system forthe collection and analysis of quality records resulting from theprocurement , manufacturing, inspection and use of articles andmaterials. Quality information shall be promptly disseminated toall concerned areas within the contractor’s organization and toj.nvolvedsuppliers when problems or deficiencies are detected.

4.2.5.1 Analvsis of Records. The contractor shall conductanalysis of quality records for the purpose of:

a. Identifying quality trends and taking appropriatecorrective action.

b. Establishing confidence levels for products,processes and suppliers by the review of objectiveevidence of conformance. o

c. Increasing the efficiency of inspection andmanufacturing operations by the judiciousconsolidation of records or operations when it canbe demonstrated that such records orof no value to the program or can bemore effective manner.

4.2.5.2 Completed Records

operations arecombined in a

4.2.5.2.1 Identification and Traceability. The contractorshall establish a system for identification, traceability andcontrol of parts, materials, and assemblies from acquisition(purchasing) through manufacturing, assembly and delivery. Flightand critical items shall reguire individual identification anddata retrieval which includes design and manufacturingdocumentation traceable to their origin. This will provide thecapability of tracing backward from fabricated hardware to therecords or material from which the item, part and materialoriginated. Identification and retrieval shall be requiredthr~ugh all levels of higher assembly.for identification and suitable marking

4.2.5.2.2made to record

Recordinq and Retrieval.and retrieve information

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The system shill provideof space flight hardware.

Provisions shall berelating to the specific

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● test performed, test results, and processes on each ot of parts.When serialization is required, controls shall be established toensure that identification serial numbers are assigned in aconsecutive manner. Records shall indicate applicable part ortype numbers and associated detailed information.

4.2.5.2.3 Component Level Data Packaaes. The contractorshall establish and maintain data packages for all selectedcomponents . The packages shall contain the complete chronologicalhistory from the beginning of component build through final Iacceptance of the component. The selection of componentsrequiring data packages shall be b~sed on the criticality of thecomponent to the mission success of the system, singJ.e pointfailure potential, the state-of-the-art of the design orprocesses, performance levels and other pertinent factors. Theterm component, as used herein, means an assembly, subassembly, orcombination of parts mounted together, normally capable ofindependent operation and performing a discrete function.Examples are: transmitter; power supply; reaction control unit;

Iwhich are normally tested as separate units. A part is not acomFonent. A data package is required for each serial number ofthe flight and qualification items, including spares, and shallinclude as a minimum the following:

a.

b.

c.

d.

e.

f.

9.

h.

Complete component build history starting at thelowest level of assembly.

Complete build inspection and test records,including physical and functional discrepancies,their resolution, and repair and rework history.

Test history including failures and anomalies duringcomponent test, resolution, and retest.

Cumulative operating time or number of cycles whenapplicable, or specified by another requirement.

Component as–built configuration description.

Records reflecting traceability of parts, materials,and subassemblies installed.

Storage history.

History of the component from the time it is firstintegrated into a higher assembly, to include;initial installation date; removal date(s); reasonfor removal; discrepancy and failure history; andtraceability references to all inspection,discrepancy, failure, rework, repair and retestpaperwork.

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4.2.5.2.4 Vehicle Level Data Packaqcs. The contractorshall establish and maintain a data package for each serialnumbered vehicle. The data package shall contain the completeintegration and test history starting with subsystem integrationand continuing through final acceptance test of the vehicle. Eachpackage shall contain as a minimum the following principal data:

a.

b.

c.

d.

e.

f.

9.

h.

i.

Build Log

Inspection History

Chronological Test History

As-built Configuration Status

A record of failure, anomalies, variations, anddeviations identified during vehicle level or systemlevel test (including any retest) and theirresolution.

A record of failures, anomalies, variations, anddeviations identified by the Material Review Boardfor vehicle details.

Component/equipment time recording status on timesensitive items.

Modification history including a list anddescription on any modification approved andscheduled for retrofit.

Installation history of traceable componentsincluding removal aid replacement his~ory.

4.2.5.2.5 Data Packaae Review. The contractor shallconduct vehicle and component data package reviews including thereview of each critical hardware item and major hardware componentof each space and launch vehicle. The reviews shall verify thatall hardware, parts, materials, and components, have beenmanufactured and tested in accordance with current designdocumentation, test procedures, and related documentation. Thereview effort shall ensure that:

a. Discrepancies are documented, and dispositions andcorrective actions are evaluated against appropriatecriteria and previous history data.

b. Anomalies noted or observed during review aredocumented, analyzed, evaluated, and dispositioned.

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c. Records are progressively reviewed and made part ofthe overall acceptance criteria.

4.3 FACILITIES AND STANDARDS

4.3.1 Drawinqs, Documents, and Chanqes. Product qualityshall be a major consideration in the contractor’s design anddevelopment efforts. The contractor shall ensure that drawings,specifications, and technical documents and changes theretocontain adequate requirements and criteria for determining andcontrolling the quality of all items purchased or produced by thecontractor. A procedure shall be established to identify,analyze, and report engineering documentation errors. Correctivemeasures shall be initiated when analysis indicates errors arebeyond the predetermined acceptable limits.

4.3.2 Desiqn Reviews. The contractor’s internal designreview program shall include participation of the QualityAssurance, Manufacturing, Engineering Speciality Organizations,and others that are users of design documentation. This shouldconsist of review and approval of all design disclosure technicaldocumentation, and changes thereto, prior to formal documentrelease. The review shall provide for independent evaluation bypersonnel knowledgeable and experienced in the quality assurance

●and control aspects of the manufacturing process. As a minimumthe following characteristics shall be considered:

a.

b.

c.

d.

e.

f.

9.

Features that enhance the practicability ofinspection, measurement, and verification ofconformance to design requirements, includingacceptance requirements.

Adequacy of provisions to perform testing to verifyfunctional integrity and specified performance.

Allocation of test points for maintainabilityconsideration.

Identification of unnecessary and unrealistic designcomplexity.

Evaluation of the extent to which single pointfailure modes and mechanisms have been eliminated,or compensating features included.

Features that enhance ease of manufacturing.

Unique or new tooling requirements.

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h. Complete, clear, accurate, and unambiguous displayof technical requirements in drawings,specifications, other engineering documentation, andprocess standards.

i. Specification of nominal useful life, andidentification of limited life items, and storagelimits.

j. Necessity and feasibility of special evaluation orinspection methods, including destructive andnondestructive evaluations.

4.3.3 Measurina and Testina Eauipment. The contractorshall provide and maintain gages and other measuring and testingdevices necessary to assure that supplies conform to technicalrequirements . These devices shall be calibrated against certifiedmeasurement standards which have known valid relationships tonational standards at established periods to assure continuedaccuracy. The objective is to assure that inspection and testequipment is adjusted, replaced or repaired before it becomesinaccurate. The calibration of measuring and testing equipmentshall be in conformity with military specification MIL–STD–45662.In addition, the contractor shall insure the use of only suchsubcontractor and vendor sources that depend upon calibrationsystems which effectively control the accuracy of measuring and otesting equipment.

4.3.4 Production Toolina Used as a Media of Inspection.The contractor shall control production tooling used as a mediaof inspection to assure continued accuracy between periods of toolproofing.

4.3.4.1 Records. The contractor shall maintain records oftool proofing which provide for each tool the date last proofed,condition found, maintenance performed and date of next proofing.

4.3.4.2 Intervals. The contractor shall analyze therecords of tool proofing in order to shorten intervals as requiredto assure continued accuracy, or to lengthen intervals when theresults of previous tool proofing provide definite indicationsthat such action does not adversely affect the accuracy of thetool.

4.4 CONTROL OF PURCHASES

4.4.1 ~ponsibility. The contractor shall establish asupplier quality program in accordance with MIL-STD-1535.

4.4.1.1 Source Inspection. The contractor shall provideresident or itinerant quality assurance representative(s) at

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● subcontractor and vendor facility(s) to provide surveillance ofthe contractor requirements. The requirement for a residentquality assurance representative shall be based on item design,mission criticality, subcontractor or supplier past performance,and other pertinent factors. The contractor shall haveinstructions for each resident or itinerant quality assurancerepresentative to delineate their responsibility and authority atthe subcontractor or vendor facility.

4.4.1.2 Group I Source Inspection. Group I purchases, asdefined in MIL-STD–1535, shall be inspected at the source by thecontractor.

4.4.1.3 Intracontractor Work Authorization. Allintracontractor work transferred between departments, divisions,or other organizational segments shall be controlled to assurecompliance with the technical quality requirements of thecontract.

4.4.2 Purchasing Data. The contractor shall develop andmaintain a matrix of all the quality assurance requirementsimposed by the item specification(s), this standard, and thecontract versus the items being procured for the program. The Imatrix shall be used in the review of procurement documentation to (

●provide a consistent and effective application of quality programrequirements .

4.5 MANUFACTURING CONTROL

4.5.1 Production Processing and Fabrication

4.5.1.1 Certification. The contractor shall establish amethod to certify the qualification of the machines, equipment,and procedures used in complex, critical operations. Recordsshall be maintained of the qualifying test performed and theresults of such tests. Machines, equipment and procedures shallbe recertified as indicated necessary by the results of qualitytrends or when major process changes are made (i.e., such items asmaterial thickness, design, power source, capacity, voltage, ordensity).

4.5.1.2 Cleanliness, Contamination and Corrosion Control.The contractor shall review and identify the cleanliness,contamination and corrosion control requirements derived fromhardware specifications and ensure that procedures are developedto adequately protect the hardware during manufacturing, storageand transportation. Implementation of controls shall be monitoredby quality assurance on a regular basis.

●4.5.1.3 Control of Physical Environment. The contractor

shall ensure through periodic audit that the physical environment

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(such as temperature, humidity, light, arrangement of work areas,or arrangement of machines and equipment) is controlled topreclude inadvertent damage to hardware and to prevent unsafeconditions in all work and storage areas.

4.5.1.4 Critical Item Ouality Control Requirements. Thecontractor shall establish and maintain appropriate critical itemcontrol. Purchase orders for critical items shall specify specialtransportation, handling, and storage requirements. Manufacturingshall include any special instructions in the appropriate planningshop folders, process plans, log books, and related documentsc~ntrolling the manufacturing and movement applicable to in-housemanufacturing. Components or materials selected for preferentialtreatment shall be conspicuously marked or tagged to alertpersonnel of special requirements. These items shall besegregated or have distinctively marked fixtures and locations inall stock rooms, holding and staging areas. Such items shall beregularly and systematically inspected for condition of expiredtime, cycle, or calendar life. Items with expired time, cycle, orcalendar life shall be identified as nonconforming and properlydispositioned. Reviews of selected critical components shall beperiodically conducted to verify the adequacy of work instructionsand standards being used.

4.5.1.5 Electrostatic Discharqe Control Proqram.Procedures shall be established for the surveillance of the oelectrostatic discharge control program implementation. Thisshall include identification of items susceptible to electrostaticdischarge and protective features to prevent such damage. As aminimum this should include:

a. Design criteria

b. Protected work areas

c. Process controls and

d. Handling, packaging,

e. Training

and protective clothing

workmanship standards

transportation and storage

f. Marking of documentation and hardware

4.5.1.6 Nondestructive Evaluation. Nondestructiveevaluation methods, verification techniques (and attendantequipment and facilities), which are used to perform quantitativemeasurements, integrity analysis, and nondestructive testing,shall be controlled and integrated into the contractor’squalification, calibration, certification and standardsprocedures. Nondestructive evaluations for hardware flight

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● configurations shall be performed by personnel proficient andcertified in the scientific field involved. Nondestructiveevaluation methods and techniques shall be encouraged when it canbe shown they will enhance productivity, and provide increasedassurance of the quality and integrity of flight hardware.

4.5.1.7 Critical Item Verification. For each criticalitem, beginning at the start of assembly and at progressive levelsof assembly and test, the contractor shall verify that thecontract, drawing, and specification requirements have been met onall such articles and materials, procured or produced.Significant anomalies, including trends, deviations from expectednorms, and marginal conditions shall be identified. Detailedassessment of the quality of these items and their manufactureshall include:

a. Identification of potential design and layoutproblems which could cause latent defects ormarginal performance.

b. Verification that current manufacturing test methodsand controls are producing repeatable products.

c. A review of manufacturing problems, if any, whichcould be alleviated by additional (or revision of)engineering information.

d. Verification that critical parameters are measuredand verified by applicable test procedures.

e. Decisions, dispositions, corrective actions, orrecommendations are evaluated against appropriatecriteria and previous history data.

f. Anomalies noted or observed during review areanalyzed, evaluated and dispositioned.

9. Records are progressively reviewed and made part ofthe overall acceptance criteria.

h. Identification and resolution of the differencesbetween as-built and design documentation.

i. A review of failure and discrepancy reports toidentify underlying causes (symptoms ormanifestations) and a summary of overstress andinduced secondary failures.

4.5.2 Completed Item Inspection and Test. Prior to

●shipment of a contract end item, the contractor shall reviewobjective evidence generated during manufacturing and test of the

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1


item to assure that all work sequences have been satisfactorilycompleted and that all nonconformances have been resolved. Thecontractor shall maintain records and findings of final review.

4.5.3 Statistical Process Control. The contractor’squality assurance organization shall participate in development oftechniques used to control process variability. This shouldconsist of the independent evaluations of design disclosuretechnical documentation and manufacturing processes by qualifiedpersonnel. As a minimum, consider that:

I a. Critical quality characteristics are identified,measured, and verified.

I il. Data is collected from points of measurement.

c. Control limits and tolerance variations aremaintained within product specification limits.

d. Procedures and methods are established forpreventative and corrective actions, and feedback isprovided to design and manufacturing.

4.6 NONCONFORMING NATERIAL CONTROL

4.6.1 Responsibility. The contractor is responsible to oassure that all items submitted to the Government fcr acceptanceare in compliance with contract technical requirements. Materialnot conforming shall be segregated and controlled in accordancewith MIL-Q–9858, MIL–STD-1520, and this standard.

4.6.2 Nonconforming Material Disposition. The dispositionof nonconforming material shall be in accordance with MIL-STD–1520as supplemented by this standard. The Material Review Board isthe only contractor constituted board authorized to determine, orrecommend to the Government, disposition of nonconformingmaterial. The rights of the Government regarding acceptance orrejection of nonconforming material apply.

4.6.3 Other Dispositions. Nonconforming material that isdetermined to be unacceptable for space flight applications shallbe clearly marked to identify specific limitations. Precautionsshall be initiated to prevent the subsequent use with, orinstallation in, flight hardware.

4.6.4 Cost of Oualitv. The “cost of quality” requirementsshall include the cost data requirements of MIL–STD-1520. Thecost data will be used by management to establish measurementparameters for evaluation of manufacturing planning andmanufacturing process in attaining suitable yield and productquality.

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SECTION 5

DETAILED REQUIREMENTS

(not applicable)

–21-



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MIL-sTD–1586A (USAF)15 JUFl 89

SECTION 6

NOTES

The contents of this Notes section are intended for use byGovernment Acquisition personnel for guidance and information only.

6.1 INTENDED USE

This standard is intended for use in acquisition contractsfor selected space vehicles, upper stage vehicles, payloads, andlaunch vehicles. The standard would be cited in the contractschedule, the general provisions, or the statement of work asapplicable to specify the quality program requirements for thevehicle acquisition. Note that this standard would not normallybe used in the acquisition of other types of equipment, such asground equipment. However, many space and launch vehicleacquisition contracts also include other types of items, such asthe associated ground equipment. The wording in this standardstates that only the requirements of MIL–Q–9858 would be imposedby this standard for the ground equipment or other elements ofthe acquisition that are not part of the vehicle. Specificwording in the Statement of Work of the contract is required to

●achieve any other interpretation.

There may be acquisition contracts for some other type ofequipment requiring high reliability where the special qualityprogram requirements for vehicles as stated in this standardshould be applied. For those equipments, a statement should beincluded in the contract or the statement of work that the words“space and launch vehicle” in this standard are to beinterpreted as the applicable equipment. Therefore therequirements in the standard for space and launch vehicles wouldbe interpreted as applying to the quality program requirementsfor the acquisition of the applicable equipment. Specificwording in the Statement of Work or the contract is required toavoid any possible misinterpretation or misapplication.

6.2 UORED APPLICATION

The quality program requirements in each contract should betailored to the needs of that particular acquisition. Militaryspecifications and standards need not be applied in theirentirety. Only the minimum requirements needed to provide thebasis for achieving the quality standards required should beimposed. The cost of imposing each requirement of this standardshould be evaluated by the program office against the benefitsthat should be realized. However, the risks and potential costs

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I

I

of not imposing requirements. mus.talso be considered. Alltailored applications of this standard shall be clearlyidentified in the compliance document section of the Statementof Work of the contract.

6.3 ‘DATA..ITEB’DESCRIPTION

When this standard is used in an acquisition and data arerequired to be delivered, the data requirements identified belowshall be developed as specified by an approved Data ItemDescription (DDForm 1664) and delivered in accordance with theapproved COntraCt Data Requirements List (CDRL), incorporatedinto the contract. For those acquisitions that require both aQuality Program Plan and a Software Quality Program Plan, it isrecommended that the remarks block of the CDRL be annotatedrequiring the plans to be combined and submitted as a singleplan. When the provisions of DOD FAR Supplement, Part 27,Sub-Part 27.410-6 (DD Form 1423) are invoked and the DD Form1423 is not used, the data specified below shall be delivered bythe contractor in accordance with the contract or purchase orderrequirements. Deliverable data required by this standard iscited in the following paragraphs.

1

Paragraph No. Data Requirement Title Applicative DID No.

4.1.1 Quality Program Plan DI-QCIC-80369A o4.1.1 Software Quality Program Plan DI-QCIC-80572

(Data item descriptions related to this standard, and identifiedin Section 6 will be approved and listed as such in DoD501O.12-L, Acquisition Management System and Data RequirementsControl List (AMSDL). Copies of data item descriptions requiredby the contractors in connection with specific acquisitionfunctions should be obtained from the Naval Publications andForms Center or as directed by the contracting officer.)

6.4 SUBJECT TERM (KEY WORD) LISTING

.Inspections

.ManufacturingQualityQuality :prog,r.am:Reco,rds.T,esting

6.5 CROSS REFERENCE MATRIX TO MIL–O–9858

The cross reference matrix relating the paragraphs in thisstandard to the corresponding MIL-Q–9858 paragraphs is shown inTable I.

o

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TABLE I. CROSS REFERENCE MATRIX TO MIL–Q–9858

Paragraph.in Corresponding MIL-Q-9858this standard paragraph identification

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

1.1 PURPOSE ........................................... 1.21.2 APPLICATION ...................................... 1.1

2. REFERENCED DOCUMENTS.. ............................ 2.

2.1 GOVERNMENT DOCUMENTS. ............................ 2.12.2 ORDER OF PRECEDENCE .............................. 1.4

3. DEFINITIONS .......................................

4. GENERAL REQUIREMENTS FOR THE QUALITY PROGRAM ......

4.1 GENERAL .......................................... 1.3

4.1.1 Quality Program Plans.. ........................

4.1.2 Policies and Procedures ........................

4.1.3 Management Reviews.. ...........................

4.1.4 Quality Audits .................................

4.1.5 Quality Program at Field Locations .............

4.1.6 Software Quality Program. ......................

4.2. QUALITY PROGRAM MANAGEMENT. ...................... 3.

4.2.1 Organization ......... .......................... 3.1

4.2.2 Responsibility ................................. 3.1

4.2.3 Initial Quality Planning. ...................... 3.2

4.2.3.1 Skill Requirements. ...........................4.2.3.2 Training .....................................4.2.3.3 Certification of Personnel ....................4.2.3.4 Recertification ...............................4.2.3.5 Records .......................................

4.2.4 Work Instructions .............................. 3.3

4.2.4.1 Manufacturing and Test Planning ...............

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MIL-sTD-1586A (U5AF)15 JUN 89

TABLE I. CROSS REFERENCE MATRIX TO MIL–Q–9858 (continued)

Paragraph in Corresponding MIL-Q-9858this standard paragraph identification

4.2.4.2 Workmanship ............................... ....4.2.4.2.1 Standards ....................................4.2.4.2.2 Visual Aids ...................................

4.2.5 Records ........................................

4.2.5.1 Analysis of Records.. .........................4.2.5.2 Completed Records .............................

4.2.5.2.1 Identification and Traceability ..............4.2.5.2.2 Recording and Retrieval ......................4.2.5.2.3 Component Level Data Packages ................4.2.5.2.4 Vehicle Level Data Packages ..................4.2.5.2.5 Data Package Review. .........................

4.3. FACILITIES AND STANDARDS. .......................

4.3.1 Drawings, Documents, and Changes ...............

4.3.2 Design Reviews .................................

4.3.3 Measuring and Testing Equipment ................

3.4

4.

4.1

4.2

4.3.4 Production Tooling Used as a Media of Inspection 4.3

4.3.4.1 Records .......................................4.3.4.2 Intervals .....................................

4.4. CONTROL OF PURCHASES.. ........................... 5.

4.4.1 Responsibility .................................. 5.1

4.4.1.1 Source Inspection ..............................4.4.1.2 Group I Source Inspection .....................4.4.1.3 Intracontractor Work Authorization .............

4.4.2 Purchasing Data ................................. 5.2

4.5. MANUFACTURING CONTROLS. .......................... 6.

4.5.1 Production Processing and Fabrication ........... 6.2

4.5.1.1 Certification ..................................4.5.1.2 Cleanliness, Contamination, and Corrosion Control4.5.1.3 Control of Physical Environment ................4.5.1.4 Critical Item Quality Control Requirements .....

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MIL–sTD-1586A (uSAF)15 JUN 89

TABLE I. CROSS REFERENCE MATRIX TO MIL–Q–9858 (continued)

Paragraph in Corresponding MIL-Q-9858this standard paragraph identification

4.5.1.5 Electrostatic Discharge Control Program ........4.5.1.6 Nondestructive Evaluation ......................4.5.1.7 Critical Item Verification .....................

4.5.2 Completed Item Inspection and Test .............. 6.3

4.5.3 Statistical Process Control ..................... 6.6

4.6. NONCONFORMING MATERIAL CONTROL ................... 6.5

4.6.1 Responsibility ....................................

4.6.2 Nonconforming Material Disposition ..............

4.6.3 Other Dispositions. .............................

4.6.4 Cost of Quality ................................. 3.6

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

6. NOTES ............................................... 8.

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

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

6.3 DATA ITEM DESCRIPTION .............................

(The following subjects in MIL-Q-9858 are not supplementedin this standard)

— Corrective Action... .............................. 3.5Use of Contractor’s Inspection Equipment .......... 4.4Advanced Metrology Requirements ................... 4.5

— Materials and Materials Control ................... 6.1— Handling, Storage and Delivery .................... 6.4— Indication of Inspection Status ................... 6.7— Government Inspection at Subcontractor or Vendor. . 7.1

Government Property. .............................. 7.2

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MIL-STD-1586A (USAF)15 JUN 89.

6.6 CHANGES FROM THE PREVIOUS ISSUE.

This issue of MIL-STD-1586 is a revision that incorporates anumber of small changes. The location of these changes from theprevious issue are indicated by a vertical bar in the margins.This was done as a convenience only and the government assumes nolibility whatsoever for any inaccuracies in these notations.Bidders and contractors are cautioned to evaluate the requirementsof this document based on the entire content irrespective of themarginal notations and relationship to the last previous issue.

CustodiansAir Force - 19

Preparing ActivityAir Force - 19

(Project No. QCIC-O1O9).Document 1965b/Arch 1319b

I

-28- +M.GOVERNMENT PRINTING OmlCE: 19s9 1C4034/U2LW

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DOC”MENTN”M ER

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2. DOCUMENT TITLE QIJALITY pROG~ REQUIREMENTS FOR SPACE ~DIL- STD - 15 6A (USAF) LAuNCH VEHICLESNAME OF S“BM,TT,NO ORGAN, ZAT,ON 4, TVPEOP OFIGANIZATION ,M.rk me,

•1vENDOR

❑ USER

hDORESS (S1”.1. CIIY. S,alc, ZIP Cede,

❑ MAN”F.CT”RER

❑ 0TH,13,SDeC,fy,

,ROBLEM AREAS

, P.,qrsph Nu,nt., snd word, ng

b. R-o,nm.”dod Wording,

. . R.m.a”/R.tlo”alc 10, R~Omnnnd”iOn:

3EMARKS

NAME OF SUB MWTER ,L=t, mr.t, WJ - ODtW.I b. WORK TELEPHONE NUMBER (l.c!.dc Awcode) –Ob.tl. n.,

IA ILING ADDRESS ,Shc,,. C,ty. S,.,,. Z,P C&, -0,,,. ”,, 8, DATE OF SUBMISSION (Y YMMDD)

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NOTICE ok’CANCELLATION

MIL-STD-1586A (USAF)NOTICE 1May 31, 1995

MILITARY STANDARD

QUALITY PROGRAM REQUIREMENTSFOR

SPACE AND LAUNCH VEHICLES

MIL-STD-1586A (uSAF), dated 15 June 1989, is hereby canceledwithout replacement. Future acquisitions should refer to anacceptable non-Government Standard on quality systems, such asInternational Organization for Standards (1S0) 9001, ~’Systems,Quality--Model for Quality Assurance in Design/Development,Production, Installation and Servicing”; American NationalStandards Institute (ANSI)/American Society for Quality Control(ASQC) Q9001, “Quality Systems--Model for Quality Assurance i.nDesign, Development, Production, Installation, and Servicing”, oran equivalent quality management system.

(DoD activities may obtain copies of 1S0 9001 and ANSI/ASQCQ9001 from the Standardization Document Order Desk, 700 RobbinsAvenue, Building.4D, Philadelphia, PA 19111-5094. The privatesector and other Government agencies may purchase copies fromANSI, 11 West 42nd Street, New York, NY 10036, and ASQC CustomerService Department, P. O. Box 3066, Milwaukee, WI 53201-3066. )

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

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