1、MIL-HDBK-798 m 9999970 OI.190540 632 SENSITIVE MIL-HDBK-798WR) 4 February 1594 MILITARY HANDBOOK SYSTEM ENGINEERS DESIGN FOR DISCARD HANDBOOK AMSC NIA DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. AREA GDRQ Provided by IHS Not for Resale No reproduction or network
2、ing permitted without license from IHS -,-,-FOREWORD l. This military handbook is approved for use by all Activities and Agencies of the Department of the Army and is available for use by all Departments and Agencies of the Department of Defense. 2. Beneficial comments (recommendations, additions, a
3、nd deletions) and any pertinent data that may be of use in improving this document should be addressed to Commander, US Army Armament Research, Development, and Engineering Center, Am: SMCAR-BAC-S, Picatinny Arsenal, NJ 07806-5000, by using the self-addressed Standardization Document Improve- ment P
4、roposal (DD Form 1426) appearing at the end of this document or by letter. 3. This handbook was developed under the auspices of the US Army Materiel Commands Engineering Design Handbook Program, which is under the direction of the US Army Industrial Engineering Activity. 11 Provided by IHS Not for R
5、esale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-798 7499970 0390542 405 . MIL-HDBK-798(AR) CONTENTS FOREWORD . i LIST OF TABLES . x LIST OF ABBREVIATIONS AND ACRONYMS . x PART ONE GENERAL CHAPTER 1 INTRODUCTION 1- 1 PURPOSE . 1-1 1-2 SCOPE 1-1 1-3 HANDBOOK OVERVI
6、EW . 1-1 BIBLIOGRAPHY 1-2 2- 1 2-2 O 2-3 2-4 2-5 2-6 2-7 2-8 2-9 CHAPTER 2 PHILOSOPHY OF DESIGN FOR DISCARD INTRODUCTION 2-1 2-1.1 BACKGROUND . 2-1 2-1.2 DISCIPLINED APPROACH . 2-1 PERSPECTIVE . 2-1 2-2.1 NOMENCLATURE 2-1 2-2.2 NATURE OF DESIGN FOR DISCARD 2-1 2-2.3 LIMITS OF DESIGN FOR DISCARD . 2-
7、2 2-2.3.1 Psychological Barriers 2-2 2-2.3.2 Cost Barriers . 2-2 2-2.3.3 Current Practice 2-2 2-2.3.4 Flexibility of Design . 2-2 2-2.4 REALISM OF MODELS 2-3 FORM, FIT, AND FUNCTION . 2-3 COMMONALITY 2-3 MAINTENANCE LEVELS . 2-4 MAINTENANCE PROCEDURES 2-4 DESIGN TECHNIQUES 2-5 ANALYSIS AND DECISION
8、TECHNIQUES . 2-5 SYSTEM-ENGINEERING INTERFACES . 2-6 REFERENCES . 2-6 BIBLIOGRAPHY 2-6 3-1 3-2 3-3 3 -4 3-5 3-6 3-7 3-8 3-9 CHAPTER 3 ADVANTAGES AND CONSTRAINTS INTRODUCTION 3-1 LIFE CYCLE COSTS . 3-1 PRODUCIBILITY 3-1 MANPOWER AND SKILLS . 3-2 OPERATIONAL READINESS 3-2 TRANSPORTATION REQUIREMENTS .
9、 3-2 MOBILITY . 3-2 PACKAGING, HANDLING, AND STORAGE 3-2 SUPPORT EQUIPMENT . 3-2 3-10 DOCUMENTATION . 3-3 3-1 I PEACETIME vs WARTIME 3-3 3-12 SHORT TERM vs LONG TERM 3-3 REFERENCE 3-3 . O . . BIBLIOGRAPHY 3-4 . 111 Provided by IHS Not for Resale No reproduction or networking permitted without licens
10、e from IHS -,-,-MIL-HDBK-798 9999970 0390543 341 m MIL-HDBK-798(AR) CHAPTER 4 TECHNOLOGY SURVEILLANCE 4- 1 INTRODUCTION 4. 1 4-2 GOVERNMENT RESEARCH . 4-1 4-3 ACADEMIC RESEARCH . 4-1 4-4 INDUSTRY RESEARCH 4-2 4-5 USING CURRENT TECHNOLOGY vs PUSHING THE STATE OF THE ART . 4-2 REFERENCES . 4.2 5- 1 5-
11、2 5-3 5 -4 5-5 5 -6 PART TWO DESIGN CONSIDERATIONS CHAPTER 5 DIAGNOSTICS INTRODUCTION 5-1 5-1.1 CHARACTERIZATION . 5-1 5-1.2 TESTS AND RISKS 5-1 5-1.3 SIMPLE MODELS FOR FAILURE . 5-2 5-1.4 ORGANIZATION OF KNOWLEDGE ABOUT POTENTIAL FAILURES . 5-2 TESTABILITY . 5-3 5-2.1 MECHANICAL . 5-3 5-2.2 ELECTRO
12、NICS, ELECTRICAL, AND ELECTROMECHANICAL 5-3 5-2.3 HYDRAULICS AND PNEUMATICS 5-4 5-2.4 OPTICAL AND ELECTRO-OPTICAL 5-4 TECHNOLOGIES OF TESTING 5-4 5-3.1 INFLUENCE OF INNOVATION . 5-4 5-3.2 CATEGORIES . 5-5 FUNCTIONAL TESTING . 5-6 FUNCTIONAL GROUPING . 5-6 APPLICATIONS AND IMPACTS 5-6 5-6.1 MECHANICA
13、L . 5-6 5-6.2 ELECTRONICS 5-7 5-6.3 ELECTRICAL AND ELECTROMECHANICAL 5-8 5-6.4 HYDRAULICS AND PNEUMATICS 5-9 5-6.5 OPTICAL AND ELECTRO-OPTICAL 5-10 REFERENCES . 5-11 BIBLIOGRAPHY 5-11 CHAPTER 6 PHYSICAL ARRANGEMENT 6-1 INTRODUCTION 6-1 6-2 MODULAR CONSTRUCTION 6-1 6-3 ACCESS . 6-2 6-4 SPATIAL PARTIT
14、IONING . 6-2 6-5 FUNCTIQNAL PARTITIONING 6-2 6-6 SIMILAR-PART PARTITIONING . 6-2 6-7 RELIABILITY PARTITIONING 6-3 6-8 COST PARTITIONING . 6-3 6-9 TESTABILITY PARTITIONING 6-3 6- 10 APPLICATIONS AND IMPACTS 6-3 6-10.1 MECHANICAL . 6-3 6-10.2 ELECTRONICS 6-4 6- 10.3 ELECTRICAL AND ELECTROMECHANICAL 6-
15、5 6-10.4 HYDRAULICS AND PNEUMATICS 6-5 6- 10.5 OPTICAL AND ELECTRO-OPTICAL 6-6 REFERENCES . 6-7 BIBLIOGRAPHY 6-7 iv Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-7- 1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 8- I 8-2 8-3 8 -4 8-5 MIL-HDBK-798 m 7777970 03905
16、44 288 m MIL-HDBK-798(AR) CHAPTER 7 MATERIAL SELECTION INTRODUCTION 7-1 STRATEGIC VALUE 7-1 COST 7-1 REPAIRABILITY 7-2 DISPOSAL COST AND SALVAGE VALUE 7-2 PACKAGING, HANDLING, AND STORAGE REQUIREMENTS 7-3 PHYSICAL CHARACTERISTICS 7-2 APPLICATIONS AND IMPACTS 7-3 7-8.1 MECHANICAL . 7-3 7-8.2 ELECTRON
17、ICS 7-4 7-8.3 ELECTRICAL AND ELECTROMECHANICAL 7-4 7-8.4 HYDRAULICS AND PNEUMATICS 74 7-8.5 OPTICAL AND ELECTRO-OPTICAL 7-5 CHAPTER 8 FABRICATION INTRODUCTION 8-1 PRODUCIBILITY 8-1 . 8-2.1 DESIGN 8-1 8-2.2 PRODUCTION PLANNING 8-2 8-2.3 PROTOTYPING 8-2 FABRICATION TECHNIQUES 8-2 REPAIRABILITY AND DUR
18、ABILITY . 8-3 APPLICATIONS AND IMPACTS 8-3 8-5.1 MECHANICAL . 8-3 8-5.2 ELECTRONICS 8-3 8-5.3 ELECTRICAL AND ELECTROMECHANICAL 8-4 8-5.4 HYDRAULICS AND PNEUMATICS 8-4 8-5.5 OPTICAL AND ELECTRO-OPTICAL 8-4 REFERENCES 8-4 . PART THREE SYSTEM CONSIDERATIONS CHAPTER 9 INFORMATION FLOW AND DOCUMENTATION
19、9- I INTRODUCTION 9-1 9-2 SCHEDULE 9-1 9-2.1 PLANNING . 9-1 9-2.2 PROJECT ENFORCEMENT 9-2 9-3 FUNCTIONAL RESPONSIBILITIES . 9-2 9-4 INFORMATION FLOW 9-3 9-5 DOCUMENTATION RESPONSIBILITIES . 9-3 9-7 LEVEL OF DOCUMENTATION DETAIL 9-3 9-6 REPORTS . 9-3 9-8 AUDIT TRAIL . 9-4 BIBLIOGRAPHY 9-4 CHAPTER 10
20、ANALYSIS AND DECISION TECHNIQUES 10- 1 INTRODUCTION 11 O- 10-2 COST ELEMENTS 10-1 10-3 FRONT-END ANALYSIS . 10-2 10-4 TRADEOFF ANALYSES 10-2 V Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-798 m 9999970 0190545 L14 MIL-HDBK-798(AR) 10-5
21、 LEVEL OF REPAIR ANALYSIS 10-2 10-6 LONG-TERM MILITARY GOALS 10-4 10-7 SYSTEM REQUIREMENTS . 10-5 REFERENCES 10-5 BIBLIOGRAPHY 10-5 CHAPTER 11 INTERFACE WITH R&M ENGINEERING 1 1- 1 INTRODUCTION 11 . 1 1 1-2 RELIABILITY ENGINEERING . 11 . 1 11-2.1 MISSION RELIABILITY . 11-1 11-2.2 OPERATIONAL READINE
22、SS AND SUSTAINABILITY . 11-1 11-3 RELIABILITY-CENTERED MAINTENANCE 11-2 11-4 MAINTAINABILITY ENGINEERING . 11-2 11-5 TESTABILITY ENGINEERING 11-2 REFERENCES . 11-2 BIBLIOGRAPHY 11-2 CHAPTER 12 INTERFACE WITH MANPRINT 12- 1 INTRODUCTION 12-1 12-2 HUMAN FACTORS ENGINEERING 12. 1 12-3 MANPOWER . 12-1 1
23、2-4 PERSONNEL . 12-1 12-5 TRAINING . 12-2 12-6 HEALTH HAZARD ASSESSMENT 12-2 12-7 SYSTEM SAFETY . 12-2 REFERENCES . 12-2 BIBLIOGRAPHY 12-2 CHAPTER 13 EFFECTS ON SYSTEM SUPPORT 13-1 INTRODUCTION 13-1 13-2 MAINTENANCE CONCEPT . 13-1 13-2.1 FUNCTIONAL LAYOUT OF SYSTEM 13-1 13-2.2 HARDWARE INDENTURE LEV
24、EL . 13-1 13-2.3 MALFUNCTION DETECTION AND DIAGNOSIS . 13-1 13-2.4 MAINTENANCE SKILLS 13-2 13-3 INTEGRATED LOGISTIC SUPPORT (ILS) . 13-2 13-3.1 ELEMENTS OF ILS 13-2 13-3.2 EFFECTS OF DESIGN FOR DISCARD 13-2 13-4 LOGISTIC SUPPORT ANALYSIS (LSA) . 13-3 13-5 INVENTORY EFFECTS . 13-3 13-6 REPLENISHMENT
25、. 13-4 13-7 MAINTENANCE TRAINING 13-4 13-8 MAINTENANCE MANUALS 13-4 REFERENCES . 13-4 BIBLIOGRAPHY 13-4 CHAPTER 14 EVALUATION OF ALTERNATIVE ITEMS 14- 1 INTRODUCTION 14. 1 14-2 EVALUATION CRITERIA FOR SELECTION . 14-1 14-2.1 LIFE CYCLE COST 14-1 14-2.2 LEVEL OF REPAIR ANALYSIS (LORA) 14-2 vi Provide
26、d by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-798 9999970 0390546 050 MIL-HDBK-798(AR) 14-2.3 OTHER CRITERIA . 14-2 14-3 QUALITY ASSURANCE . 14-2 14-3.1 DURING PRODUCTION . 14-2 14-3.2 AT ACCEPTANCE . 14-3 14-4 CONFIGURATION CONTROL . 14-3 14-
27、5 DESIGN REVIEWS . 14-4 14-5.1 SYSTEM DESIGN REVIEW 14-4 14-5.2 PRELIMINARY DESIGN REVIEW 14-4 14-5.3 CRITICAL DESIGN REVIEW . 14-4 14-5.4 OTHER REVIEWS AND AUDITS 14-4 REFERENCES . 14-5 BIBLIOGRAPHY 14-5 PART FOUR PROGRAM CONSIDERATIONS CHAPTER 15 COST CONTROL 15-1 INTRODUCTION 15-1 15-2 DESIGN TO
28、COST 15-1 15-3 LIFE CYCLE COST ESTIMATES . 15-1 15-3.1 MODELS . 15-2 15-3.2 PARAMETERS OF THE MODELS . 15-2 15-4 PRODUCIBILITY ENGINEERING AND PLANNING (PEP) 15-2 REFERENCES . 15-3 BIBLIOGRAPHY 15-3 CHAPTER 16 ACQUISITION ALTERNATIVES 16- 1 INTRODUCTION 16-1 16-2 PRODUCT IMPROVEMENT OR REDESIGN 16-1
29、 16-2.1 ENGINEERING CHANGE PROPOSAL (ECP) 16-1 16-2.2 PRODUCT IMPROVEMENT PROGRAM (PIP) 16-1 16-3 NONDEVELOPMENTAL ITEMS . 16-2 16-4 NEW DEVELOPMENT ITEMS . 16-2 16-4.1 SYSTEM INTEGRATION 16-2 16-4.2 ADVANCING THE STATE OF THE ART . 16-2 REFERENCE . 16-2 BIBLIOGRAPHY 16-2 CHAPTER 17 CONTRACTUAL ELEM
30、ENTS 17-1 INTRODUCTION 17-1 17-2 CRITERIA FOR SOURCE SELECTION . 17-1 17-3 STATEMENT OF WORK . 17-1 17-3.1 PRINCIPLES 7- 1 17-3.2 SAMPLE CLAUSES . 17-2 17-3.3 DATA ITEMS 17-2 17-4 INCENTIVE CLAUSES 17-2 17-4.1 FIXED-PRICE CONTRACTS 17-2 17-4.2 COST-REIMBURSEMENT CONTRACTS . 17-3 17-5 SPECIFICATION R
31、EQUIREMENTS . 17-3 17-6 INSPECTION AND ACCEPTANCE 17-3 17-7 WARRANTIES 17-3 17-8 SECOND SOURCING . 17-4 REFERENCES . 17-4 BIBLIOGRAPHY 17-4 vii Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-M1L-HDBK”796 qYqq770 0390547 T97 m MIL-HDBK-798(AR) APP
32、ENDIX A . A-1 APPENDIX B . B- 1 APPENDIX C . C- 1 APPENDIX D . D- 1 GLOSSARY G-1 INDEX I- 1 SUBJECT TERM (KEY WORD) LISTING . ST- I . v111 Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-0 Table MIL-HDBK-798 m 9999970 0190548 923 m LIST OF TABLES
33、Title Page No. 10-1 PAIJvlAN Repair Versus Discard Model (PALMAN) 10-2 10-2 by Hardware Versus Manpower Comparability Analysis Methodology (HARDMAN) 10-3 10-3 Early Comparability Analysis (ECA) 10-3 10-4 Optimum Supply and Maintenance Model (OSA“) 10-4 10-5 Logistic Analysis Model (LOGAM) 10-4 ix Pr
34、ovided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-798 9999970 OL905LI9 8bT m MIL-HDBK-798(AR) LIST OF ABBREVIATIONS AND ACRONYMS ABCA = American, British, Canadian, and Austra- lian AMC = US Army Materiel Command ARL = Army Research Laborator
35、y ARO = Army Research Office ATE = automatic test equipment BCS = baseline comparison system BIT = built-in test AR = Army Regulation ASARC = Army System Acquisition Review Council BDAR = battlefield damage assessment and repair BITE = built-in test equipment CAD = computer-aided design CAE = comput
36、er-aided engineering CAM = computer-aided manufacturing CDR = critical design review COEA = cost and operational effectiveness analysis CPAF = cost-plus-award fee CPFF = cost-plus-fixed fee CPIF = cost-plus-incentive fee DFARS = DoD FAR Supplement DoD = Department of Defense DoDI = Department of Def
37、ense Instruction DS = direct support DSU = direct support unit DTC = design to cost DTIC = Defense Technical Information Center DA = Department of the Army DoDD = Department of Defense Directive DTLCC = design to life cycle cost DTOSC = design to operations and support cost DTUPC = design to unit pr
38、oduction cost ECA = early comparability analysis ECP = engineering change proposal ESD = electrostatic damage FAR = Federal Acquisition Regulation FFP = firm-fixed price EEEL = Electronics and Electrical Laboratory FMECA = failure mode, effects, and criticality analy- sis FMS = foreign military sale
39、s FPI = fixed-price incentive GS = general support GSU = general support unit HFE = human factors engineering ILS = integrated logistic support LCC = life cycle cost LED = light-emitting diode LOGAM = logistic analysis model LORA = level of repair analysis LRU = line-replaceable unit LSA = logistic
40、support analysis LSAR = Logistic Support Analysis Record MAC = maintenance allocation chart MANPRINT = manpower and personnel integration MATE = modular ATE MICOM = US Army Missile Command MOS = military occupational specialty MPT = manpower, personnel, and training MTTF = mean times to failure NATO
41、 = North Atlantic Treaty Organization ND1 = nondevelopmental item NIST = National Institute of Standards and Tech- NTIS = National Technical Information Service 0&M = operation and maintenance O&S = operations and support nology OSAMM = optimum supply and maintenance model PC = printed circuit PDR =
42、 preliminary design review PEP = producibility engineering and planning P31 = preplanned product improvement PIP = product improvement program PM = preventive maintenance ppm = parts per million QQPRI = qualitative and quantitative personnel requirements information R&M = reliability and maintainabi
43、lity RAM = reliability, availability, and maintainability RCM = reliability-centered maintenance RDEC = research, development, and engineering RDTE = research, development, test, and evaluation center RFP = request for proposals RIW = reliability improvement warranty SDR = system design review SMR =
44、 source, maintenance, and recoverability SOW = statement of work SRU = shop-replaceable unit SSEB = source selection evaluation board ST1 = scientific and technological information TDP = technical data package TMDE = test, measurement, and diagnostic equip- ment TOE = table of organization and equip
45、ment TFs = test program set TQM = total quality management UPC = unit production cost UUT = unit under test VAST = versatile avionics shop tester WSEIAC = Weapon System Effectiveness Industry Advisory Committee Provided by IHS Not for Resale No reproduction or networking permitted without license fr
46、om IHS -,-,-MIL-HDBK-798 m 9999970 0390550 581 m MIL-HDBK-798(AR) PART ONE GENERAL Part One provides a perspective on this handbook and explains the reasoning behind the design for discard effort. The items, activities, and concepts that are affected by design for discard are summarized. Finally, th
47、e ways in which technology and research interact with design for discard are presented. CHAPTER 1 INTRODUCTION The purpose, theme, scope, and approach of this handbook are explained, and the contents of each chapter are very briejly summarized. 1-1 PURPOSE 1-3 HANDBOOK OVERVIEW The purpose of this h
48、andbook is to provide a reference The theme of this handbook is guide on Army materiel design and the support philosophy 1. When design for discard is added to a program, the known as “design for only the outcome of the process is different. The Out- ble concepts, techniques, and procedures for prac
49、tical come is different because engineers are putting different implementation of a design for discard program. The hand- designs into the process and because management is Using book explains different criteria for “best”. l. What design for discard means 2. Why design for discard should be implemented a. Strive to develop cost-effective maintenance and 3. What the design for disca
