MIL-STD-1540D
assure that the delivered product does not have latent material deficiencies and workmanship defects when it is determined that:
a. The product design characteristics are such that there may be hidden or dormant defects that might otherwise surface during testing at higher levels of assembly or during mission operations,
b. Testing is the most appropriate method of surfacing those defects.
5.4.2.2.2 Acceptance Methods. One or a combination of methods shall be selected to assure that accumulated defects of manufacturing and any previous operation or testing have not degraded the capability of the product to perform as designed during the mission life cycle. The selected method(s) shall be capable of surfacing all infant mortality and workmanship induced failures at each level of assembly. In general verification by testing is most efficient when:
a. The design characteristics are sufficiently complex such that
non-destructive inspection techniques (visual, x-ray, dye-penetrant, etc.) are not appropriate or cost effective, and other less costly methods are not appropriate or technically sufficient;
b. The product size and configuration is such that environmental test stresses can be effectively induced throughout the product, without concern for overstressing the product.
Programs must be able to prove that there is sufficient remaining useful life after verification testing such that the product can accomplish the mission. The least risk is incurred when this is done by qualification testing of a dedicated test article or when there is a strong and proven product heritage. The
benefit that comes with product test verification outweighs the issue associated with proving that there is remaining useful life in a product.
5.4.2.2.3 Test for Risk Mitigation. Programs shall conduct tests to confirm specification performance and that defects were not introduced by assembling and integrating products in the field, or degraded by unanticipated interaction between those integrated elements, whenever the program identifies the need to mitigate any of the following risks:
a. Mitigate technical risk - the program cannot effectively acquire data at the next higher level of assembly. The program will not be able to prove, by testing at the next higher assembly level, that the integrated assembly is functioning as designed; or the program determines that a failure at the next higher level of assembly may cause damage to other product elements or cause injury to personnel;
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