NAVY ATE And TPS Acquisition Handbook 2005
NAVYATE and TPSACQUISITIONHANDBOOK31 March 2005Published by COMNAVAIRSYSCOM PMA260,Leader of the Automatic Test & Diagnostics Standing CommitteeUnder Authority of the Navy Test and Monitoring Systems Executive Board
Table of ContentsACRONYMS . 41. INTRODUCTION. 52. POLICY FOR ACQUISITION OF ATS . 6DoD Policy . 6SECNAV Policy . 7OPNAV Policy . 7SYSCOM Policy . 8NAVAIRSYSCOM. 8NAVSEASYSCOM . 9SPAWARSYSCOM . 9Navy Test and Monitoring Systems . 93. DEFINITIONS . 9Automatic Test System . 9Automatic Test Equipment . 10Test Program Set . 10Open Systems and How They Apply to ATS . 114. OVERVIEW . 12Developing an ATS Acquisition Strategy . 12Program Manager's Authority . 12For more information . . 125. ATS ACQUISITION PROCESSES AND PROCEDURES . 14Requirements Definition . 14ATS Support Alternatives . 14CASS . 15COTS . 16Other . 17Analysis of Alternatives . 17Cost and Benefit Analyses . 18Contracting for an ATS. 19Test and Evaluation of ATS . 20Controlling Costs . 20Lessons Learned . 216. TEST PROGRAM SET ACQUISITION PROCESSES AND PROCEDURES . 22TPS Acquisition Process . 22Red Team Package . 23CASS TPS Development Training . 24TPS Procurement Checklist . 25Test and Evaluation of TPS . 25TPS Costs . 25Standard TPS Cost Management System . 25NAWCAD LKE TPS Cost Study . 27Lessons Learned . 272
7. CASS ACQUISITION PROCESSES AND PROCEDURES. 28CASS Hardware Acquisition . 28CASS Implementation Plan . 28CASS Installations, SHIPALTS and MILCON . 29Site Activation Planning Guide . 29Navy Working Capital Funded (NCWF) activities . 29Marine Corps CASS Requirements. 30CASS Support . 31Manpower and Training . 31CASS Logistics Support . 31APPENDIX 1: CASS AND RT-CASS TECHNICAL DATA & SPECIFICATIONS. 32CASS Hybrid Station basic test capability. 32CASS RF Station . 36CASS E-O Station . 39RT-CASS test capability. 41APPENDIX 2: COMMERCIAL TESTER ACQUISITION VALIDATION REQUEST . 49APPENDIX 3: DOD NON-STANDARD ATS POLICY DEVIATION APPROVAL FORM . 50APPENDIX 4 - TPS DEVELOPMENT PROCESS . 51APPENDIX 5: TPS PROCUREMENT CHECKLIST . 523
SDOUSDPEOPMSAPGSPAWARSRASSM SSPSTCMTAMST&ETEMPTPSUUTWIPTWRAAcquisition CategoryATS Management BoardAssistant Secretary of the Navy (Research,Development and Acquisition)Automatic Test EquipmentAutomatic Test SystemsConsolidated Automated Support SystemCost & Benefit AnalysisCASS Implementation PlanCommercial Tester Acquisition Validation RequestExecutive AgentExecutive Agent OfficeIntegrated Family of Test EquipmentIntegrated Logistics SupportIntermediate Maintenance ActivityIntegrated Product TeamJoint Technical ArchitectureMarine Corps Systems CommandMilestone Decision AuthorityNaval Air Systems CommandNaval Sea Systems CommandOriginal Equipment ManufacturerOverarching Integrated Product TeamOffice of Secretary of DefenseOffice of the Under Secretary of DefenseProgram Executive OfficerProgram ManagerSite Activation Planning GuideSpace and Naval Warfare Systems CommandShop Replaceable AssemblySystem Synthesis Model PlusDirector, Strategic Systems ProgramStandard TPS Cost Management SystemTest and Monitoring SystemsTest and EvaluationTest and Evaluation Master PlanTest Program SetUnit Under TestWeapons System Integrated Product TeamWeapons Replaceable Assembly4
1. IntroductionThis handbook has been developed to provide familiarization and guidance toNavy/Marine Corps System Commands and their supporting field components in determiningrequirements, planning acquisitions and managing Automatic Test Equipment (ATE) and TestProgram Sets (TPS). The goal of the information provided is to:1. Describe ATE/TPS-related policy, procedures, and processes used in both DoD andthe Navy2. Present technical information relative to the Consolidated Automated Support System(CASS), the Navy's standard ATS Family for support of all Navy electronics fromaircraft to ships and submarines at Intermediate Maintenance Activities (IMAs) bothashore and afloat as well as at Navy repair depots.3. Identify points of contact and sources of additional information, including lessonslearnedThe information in this Handbook will be updated and expanded regularly to reflect themost recent DoD and Navy policy, guidance and lessons learned for ATE and TPS. To obtain acopy of this document contact NAVAIR PMA-260D, Mr. William A. Ross at (301) 757-6907. Itmay be downloaded at http://www.acq.osd.mil/ats.5
2. Policy for Acquisition of ATSDoD PolicyOn 29 April 1994, USD (A&T) Memo “DoD Policy for Automatic Test Systems (ATS)”established policy that DoD components shall satisfy all acquisition needs for automatic testequipment hardware and software by using designated ATS families. It stated that ATScapabilities shall be defined through control of critical hardware and software elements andinterfaces to ensure DoD family tester and COTS tester and component interoperability, and tomeet future DoD test needs. This memo designated the Army's Integrated Family of TestEquipment (IFTE) and the Navy's Consolidated Automated Support System (CASS) as initialDoD families. Since then, the Marine Corps’ Third Echelon Test Set (TETS), and the JointService Electronic Combat Test Systems Tester (JSECST) have been added to the list ofapproved DoD Family Testers.DoD 5000.2-R was first published on 15 March 1996 and stated DoD ATS policy: “DoDautomatic test system (ATS) families or COTS components that meet defined ATS capabilitiesshall be used to meet all acquisition needs for automatic test equipment hardware and software.ATS capabilities shall be defined through critical hardware and software elements. Theintroduction of unique types of ATS into the DoD field, depot, and manufacturing operationsshall be minimized.”Change 1 to DoD 5000.2-R was issued on 6 October 1997 and added the requirement that“the selection shall be based on a cost and benefit analysis that ensures that the ATS chosen isthe most beneficial to the DoD over the system life cycle.” Subsequent changes to DoD 5000.2R have retained this requirement.Current OSD ATS policy, issued in July 2004 (see To minimize the life cycle cost of providing automatic test systems for weapon systemssupport at DoD field, depot, and manufacturing operations, and to promote joint serviceautomatic test systems interoperability, Program Managers shall use approved DoD ATSFamilies as the preferred choice to satisfy automatic testing support requirements. Commercialoff-the-Shelf (COTS) solutions that comply with the DoD ATS Technical Architecture shouldonly be used if the Milestone Decision Authority concurs that an approved DoD ATS Familywill not satisfy the requirement. Automatic Test System selection shall be based on a cost andbenefit analysis over the system life cycle.”The intent is to define an acquisition environment that makes DoD the smartest, mostresponsive buyer to meet our warfighters’ needs while reducing the total cost of ownership. Thiswill be accomplished through the use of ATS Families as the preferred choice to satisfyautomatic testing support requirements. OSD has designated the following DoD ATS Families: Consolidated Automated Support System (CASS) - NavyIntegrated Family of Test Equipment (IFTE) - ArmyMarine Corps Automatic Test System (MCATES) – USMC groundJoint Service Electronic Combat Systems Tester (JSECST) – USAF/Navy6
ATS selections are to be cost beneficial to DoD (not necessarily what is best for theindividual project or Service) over the life cycle. When new systems are developed, an opensystem approach shall be followed.SECNAV PolicySECNAVINST 3960.6, "DON Policy and Responsibility for Test, Measurement,Monitoring, Diagnostic Equipment and Systems, and Metrology and Calibration (METCAL)" of12 October 1990 has three main purposes:a. To establish Navy policy and responsibility for incorporating testability and diagnosticcapability into weapons platforms, weapon systems, surveillance, communications, navigationalguidance, deception/protection systems, meteorological systems, and associated support systems.b. To establish policy and responsibility for the selection, development, acquisition,standardization, application, and logistics support of test, measurement, monitoring, diagnosticequipment and systems.c. To implement the Department of Navy Metrology and Calibration (METCAL)Program, and to assign responsibilities within the Department of the Navy for METCAL.Specific policies and procedures in SECNAVINST 3960.6 relative to ATE and TPSsinclude the following: General purpose test equipment shall be used where possible. Commercially available test equipment and systems shall be used if they meetenvironmental requirements imposed by the operational mission and can be logisticallysupported. ATE should be standardized as much as possible. CASS is being developed as the Navy's standard ATE. Systems acquisition managers(program managers) will study and determine if and when it is economically practical totransition to CASS. Until then, they will continue to use their present test equipment. In the future, use of non-CASS ATE will require Assistant Secretary of the Navy forResearch, Development, and Acquisition ASN(RD&A) approval. New ATE shall not be acquired if CASS can satisfy the requirements. Acquisition and life cycle costs must be considered during the design and acquisitionprocess and in performing diagnostic capability trade-offs. TPS development and distribution costs shall be included in the life cycle cost of ATE foracquisition planning.OPNAV PolicyOPNAVINST 3960.16, "Navy Test and Monitoring Systems", of 18 January 1995implements SECNAVINST 3960.6 and assigns responsibility for Navy Test and MonitoringSystems (TAMS). It assigns NAVSEA with Lead SYSCOM responsibility for TAMS anddesignates NAVAIR as Lead SYSCOM for ATE.7
Specific policies and procedures in OPNAVINST 3960.16 relative to ATE and TPSsinclude the following: Utilize built-in-test, built-in-test equipment, general purpose test equipment, specialpurpose test equipment and/or ATE for condition monitoring, fault verification and faultisolation at each level of maintenance. The mix of equipment utilized will be establishedby the results of the testability and level of repair portions of the logistics supportanalysis process performed up-front on the system to insure the availability of adequatetest, measurement and calibration capability at the lowest cost effective maintenancelevel. Minimize the use of special purpose (peculiar) test equipment and maximize the use ofcommercial/non-developmental standardized (common) test equipment. New ATS shall not be acquired if the requirement can be satisfied by the CASS.Exceptions to the use of CASS shall require a waiver approved by ASN(RDA). Ensure that system and subsystems contractors use the same diagnostic capability (i.e., nospecial factory test equipment) that will be used under operational conditions to performfactory diagnostics for units under production. This applies specifically to ATS for field,depot and factory testing. Waivers for non-standard ATE (non-CASS) will be submitted to ASN(RDA) via CNO(N43), and waivers for remaining TAMS policy requirements will be submitted toNAVSEA, NAVAIR, SSP, and SPAWAR as appropriate.SYSCOM PolicyNAVAIRSYSCOMNAVAIRINST 13630.2D of 3 December 2003 establishes policy, assignsresponsibilities, and provides procedures for optimizing the use of CASS and associated TPSs bythe Naval Aviation Systems Team. Is assigns PMA-260, the CASS Program Manager, withresponsibility for(1) budgeting, acquisition and support of CASS,(2) budgeting and acquisition of TPSs being used on existing legacy ATE for offload toCASS, and(3) assessment of weapon system IPT TPS acquisitions prior to proposal initiation andagain prior to fielding.This instruction details the process for matching weapon system support requirements tospecific configurations of CASS and it contains the format and specific procedures for requestinga waiver to using CASS from ASN(RDA).NAVAIRINST 5400.118A of 28 May 1997 assigns PMA-260 with responsibility todevelop and maintain a generic TPS procurement package and process for use by other ProgramManagers, Assistant Program Managers Logistics (APMLs) and NAVSEA.In synopsis, PMA-260 budgets for and manages CASS itself and TPSs being offloadedfrom legacy ATE. TPSs for new weapons systems, weapon systems subsystems andcomponents, and changes to weapon systems are funded and managed by the respective ProgramManager.8
NAVSEASYSCOMNAVSEAINST 4734.1B, NAVSEA Test, Measurement and Diagnostic Equipment(TMDE) and Calibration Programs, established policy and assigns responsibilities for themanagement, operation and logistics support of NAVSEA-cognizant TMDE. It referencesSECNAV 3960.6 and requires that waivers for the use of non-standard TMDE (including ATE)be processed through SEA-04.SPAWARSYSCOMSPAWAR 4700.16M, Maintenance Policy and Procedures, requires the use of CASS asthe Navy's standard ATE. It states that the CASS system standardizes hardware and softwaretestability requirements for all future TPS development in support of SPAWAR systems andequipment. This requirement applies to all new systems with an IOC of FY92 and beyond.Existing systems will be transitioned to a CASS-compliant configuration when they undergomajor modifications/upgrade, or as is economically feasible, based on fleet priorities. It alsostates the requirement for ASN(RDA) approval for use of non-CASS ATE.Navy Test and Monitoring SystemsSECNAVINST 3960.6 and OPNAVINST 3960.16 assigned NAVSEA with LeadSYSCOM responsibility for Test a
DoD families. Since then, the Marine Corps’ Third Echelon Test Set (TETS), and the Joint Service Electronic Combat Test Systems Tester (JSECST) have been added to the list of approved DoD Family Testers. DoD 5000.2-R was first published on 15 March 1996 and stated DoD ATS policy: “DoD
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