MIL-HDBK-115B(ARMY)
standards, including verification of performance, determination of reliability and endurance, and verification of structural integrity.
5.10.3 Worse-case analysis. If the available documentation lacks sufficient test data, a worse-case analysis should be performed to develop testing criteria and procedures, including critical failure modes and limitations. Experts in the field should be contacted to identify common failure areas. The tests for item failure limits, such as overload, fatigue, vibration, and temperature, are the most convincing means of ensuring equivalence of manufacture. The Acceptance Test Procedures should define these requirements and specify the test procedures in accordance with the applicable specifications and standards. A sample Test Plan Format is provided in figure 3.
5.11 Reverse engineering cost-estimate and schedule.
5.11.1 Review. Cost estimates and schedules previously generated should be reviewed. Most of these estimates were based on a best guess, at the time, without benefit of hardware availability.
5.11.2 Development. The Reverse Engineering Cost-Estimate and Schedule should be based on the complexity of the item and the number of piece-parts/components involved. The total effort involved is dependent upon the technical data available versus the amount of data to be developed.
5.11.3 Sample cost-estimate guide. A sample Cost-Estimating Guide is provided in figure 4. These are only guidelines and most data was derived during the trial program; however, the estimates for drawing preparation, producibility studies and quality control reviews are based on years of experience.
5.11.4 Prototype values. The Reverse Engineering Cost-Estimate and Milestone Chart should be developed and included in the Candidate File. The values for prototype production and testing may be estimated at this time, and revised later in the process when actual bids are received from the manufacturers.
5.11.5 Dollar values. A dollar value for a point of diminishing returns should be established and the estimated cost to complete should be monitored throughout the process. The TDP preparation costs should not change significantly, however, as tolerances are developed and tooling requirements identified, they may affect the cost of reverse engineering.
5.12 Disassembly procedures. Disassembly procedures should be developed for each candidate to ensure functional integrity and to allow for a
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