Eric Hawley NOSSA

Phone: 301-744-6073 E-mail: eric.hawley@navy.mil

Diane Dray

Booz Allen Hamilton Phone : 301-838-3891

E-mail: dray_diane@bah.com

Joint Munitions Safety Testing (JMST) Tutorial

1

Objectives:

Familiarize students with the JMST program and process

Provide access to current AAS3Ps /JOTPs available for immediate use

Provide tailoring examples for JOTP application

Show future JMST Program of Work

Show how JMST process can be applied to solve multiple issues for functional groups in a joint environment

2

Table of Contents

Origins, Goals and Scope of JMST

Process

Accomplishments

Applications and Opportunities

3

3

Initiatives Interwoven to Enhance Support to the Joint Warfighting Environment

Initiatives

Materiel Reviews: Collaborate on Joint Weapons Safety Reviews

Requirements: Integrate Joint Weapons Safety Requirements in Joint Capabilities Integration and Development System (JCIDS)

Testing: Develop Joint Service Weapons Safety Testing Standards

Expedites safety processes and testing to field weapons to the warfighter faster.

4

The Challenge Basic munitions safety tests are used for Safety and Suitability for Service (S3) assessment as contained in STANAG 4629 (NATO 2011). DoD acquisition has challenges in safety testing of munitions:

Multiple duplicate/overlapping standards

Multiple applications/interpretations of same standard by different Services – Electrostatic Discharge – Terminology differences

Multiple (and redundant) tests conducted/Expense of Reconciling multiple standards

Users have told us acquisition takes too long

5

Joint Service Safety Testing Progression

JSST Phase II Collected all safety

tests Developed

common weapon life cycle terms

Assigned initial test categories

Result: Validated need and obtained terms of reference consensus

Refined test categories Identified inconsistent,

duplicate tests Facilitated test

standard workshops

Recommended draft system-

independent tests by life cycle

Result: Drafted list of joint tests by life cycle (Index)

Gained Joint Service agreement on Index, and Long

Drop Joint Ordnance Test Procedure (JOTP)-001 test

Updating CJCSM 3170

Recommended Way Ahead on Joint Electromagnetic Environmental

Effects (EEE) test

Draft NATO test standards

Drafting NATO Allied Ammunition

Safety and Suitability for

Service Publication documents

- Shoulder Fired - Large Caliber - Air Launched

JSSTR Phase I

JSST Phase III

JMST Phase IV

Result: Applied Index to JCIDS doc review

6

Result #1: Validated Need for Joint Service Safety Testing Requirements

Shared/Joint

Requirements

Given the increasingly joint nature of the current military conflicts, Services are increasingly hindered and delayed by the need to require duplicate and inconsistent safety tests in order to certify munitions for use, and qualify

munitions for military transportation to deployed sites.

7

Result #2: Obtained Consensus on Terms of Reference for Munitions Life Cycle

Capabilities Production Document Initial Capabilities Document

A CD B C

Capabilities Development Document

Safety test results will be detailed in the CPD.

System Independent and Dependent

Tests 1. Joint Shock Test

2. Joint Vibration Test

3. Joint Temperature Test

4. Joint EEE Test

5. …

System Independent and Dependent

Tests 1. Joint Shock Test

2. Joint Vibration Test

3. Joint Temperature Test

4. Joint EEE Test

5. …

Drives System Independent

Tests

Drives System Dependent

Tests

Generic Subsystem System - Specific Ammunition Cannon Electric Initiators Explosives Fuze Power Sources Rocket Motors Software Submunitions Unmanned Targets

Generic Subsystem System - Specific Ammunition Cannon Electric Initiators Explosives Fuze Power Sources Rocket Motors Software Submunitions Unmanned Targets

Modes / Joint Warfighting Environments Handling Forklift Handcart Crane Man Carried Underway Replenishment (VERTREP,

CONREP) Storage Protected/Environmentally - Controlled Land

Based Magazines Unprotected/Open Land Based Magazines

Transportation Wheeled Land Vehicles Rail Fixed Wing Aircraft Rotary Wing Aircraft Navy and Army Vessels Prepo /Merchant Marine/Commercial Undersea

Employment Tracked Land Vehicles Wheeled Land Vehicles Fixed Wing Aircraft Rotary Wing Aircraft Operational Navy Vessels Undersea Man Carried

Modes / Joint Warfighting Environments Handling Forklift Handcart Crane Man Carried Underway Replenishment (VERTREP,

CONREP) Storage Protected/Environmentally - Controlled Land

Based Magazines Unprotected/Open Land Based Magazines

Transportation Wheeled Land Vehicles Rail Fixed Wing Aircraft Rotary Wing Aircraft Navy and Army Vessels Prepo /Merchant Marine/Commercial Undersea

Employment Tracked Land Vehicles Wheeled Land Vehicles Fixed Wing Aircraft Rotary Wing Aircraft Operational Navy Vessels Undersea Man Carried

8

Result #3: Drafted Index of Joint Warfighting Modes for Munitions Safety Tests by Life Cycle

9

JMST and Joint Weapons Safety Working Group Roles, Responsibilities, and Relationship

JMST - an established project with munitions SMEs working to develop Joint standardized safety tests enhancing transparency and data parity in Joint Service safety reviews, material release, and acceptance.

JWSWG (Joint Weapons Safety Working Group) – this J8 Joint Staff-chartered Working Group is the National S3 Authority. Recommends harmonized safety review procedures, evaluation criteria and common safety capabilities and attributes across the DoD Components for conventional weapons.

JMST-JWSWG – JMST’s deliberations and product fall under the purview of the JWSWG and the JWSWG advises the JMST.

10

JWSWG Obtained Consensus on Munitions Safety Tests by Joint Warfighting Modes: “Index”

11

11

DSOC Established by SECDEF Memo

DSOC Task Force

Acquisition and Technology Programs - Initiative sponsored by the Acquisition and Technology Programs Task Force (ATP TF) of the Defense Safety Oversight Council (DSOC) under the Office of the Under Secretary of Defense (OUSD) for Acquisition, Technology and Logistics (AT&L) in response to the Secretary of Defense’s (SECDEF) memo on reducing preventable accidents (SECDEF 2003)

12

Army-MST and JSSTR Comparative Analysis by JWSWG: Army-MST and JSST goals similar.

Levels are different and compatible. – JSST is high level, system independent. – Army-MST is commodity specific, system dependent.

Merged Army-MST and JSST are complimentary; combined, they bridge the capabilities developer community and material review acquisition community.

– Improved consistency in safety of use policy Department-wide; compressing time, factory to foxhole.

– Increase Program development stability for the Program Manager; conserving constrained resources.

13

JMST Goals: Contribute to a more streamlined Safe Weapons Endorsement advisory

function of the JWSTAP by providing members a template for consistency in addressing JCIDS documents under review

Establish Joint weapon safety requirements early in the acquisition process by calling out the appropriate standardized Joint test document within the JCIDS documents (Initial Capability Document, Capability Development Document, Capabilities Production Document)

Enhance weapon safety by providing for common handling and storage environmental risk picture in support of a joint war fighting environment

14

JMST Scope: Guide personnel involved in the planning and execution of Safety and

Suitability for Service (S3) test documents structured under STANAG 4629 “Safety for Service Assessment Testing of Non-Nuclear Munitions” as Allied Publications

– Ammunition- Large Caliber, -Medium Caliber, -Small Caliber; -Non-Lethal; -Man emplaced demolitions

– Missile/Rocket-Air Launched; -Surface Launched; -Man carried – Explosive Ancillary; Pyrotechnics; Fuze and Ignition; Underwater;

Insensitive Munitions; Electromagnetic Environmental Effects; Software

Limitations – Scope limited to only munitions safety tests; not ALL International Test

Operations Procedures. – Only applicable to conventional test items – Not intended to be used to aid the assessment of effectiveness, reliability or

performance of a munition

15

Under the auspices of the NATO AC326 Subgroup 3, the Working Group for the Development of S3 documents developed STANAG 4629 (NATO 2011) “Safety and Suitability for Service Assessment Testing of Non-Nuclear Munitions,” a six-page standardization agreement paving the way for improved munitions type-specific joint test standards.

The S3 Working Group efforts were complimentary with the Joint Service Safety Testing recommendations, the work was linked in a dual path domestic and international process.

NATO AC326 SG3 Working Group For The Development of Safety

and Suitability for Service Documents

16

Participating NATO Nations in JMST

United States

Canada

United Kingdom

Netherlands

France

Germany

17

Joint Service Safety Testing Progression

JSST Phase II Collected all safety

tests Developed

common weapon life cycle terms

Assigned initial test categories

Validated need and obtained terms of reference consensus

Refined test categories Identified inconsistent,

duplicate tests Facilitated test

standard workshops

Recommended draft system-

independent tests by life cycle

Drafted list of joint tests by life cycle (Index)

Gained Joint Service agreement on Index, and Long

Drop Joint Ordnance Test Procedure (JOTP)-001 test

Updating CJCSM 3170

Recommended Way Ahead on Joint Electromagnetic Environmental

Effects (EEE) test

Draft NATO test standards

Drafting NATO Allied Ammunition

Safety and Suitability for

Service Publication documents

JSSTR Phase I

JSST Phase III

Phase IV JMST

Applied Index to JCIDS doc review

18

Table of Contents

Origins, Goals and Scope of JMST

Process

Accomplishments

Applications and Opportunities

19

Joint Ordnance Test Procedures (JOTP)

The US Joint Working Group publishes a commodity-specific corresponding JOTP for each AAS3P. In most cases, these two products are developed at the same time, by the same group of SMEs, and contain identical procedures.

Features of JOTPS:

Narrow coordination, can be developed quickly by a small inter-service team of SMEs, coordinated among designated service SMEs, and published

Address an immediate need by developing JOTPs in 6 to 9 months, then use JOTPs as a basis for developing NATO Allied Publications to eventually replace the JOTPs.

Designed to be retired when the corresponding AAS3P is ratified. If the NATO Allied Publication route encounters difficulties, or is delayed, then the JOTP may remain active or incorporated into a MIL-STD.

20

Benefits of the JOTP Path: The established JOTP methodology and process may be used by a joint group

to institutionalize their agreed-to best practices.

The JOTP may be used to address a non-commodity specific vulnerability, such as Electromagnetic Environmental Effects, Insensitive Munitions (notional), fuze testing and design, or Software Safety Assessment (notional).

The JOTP may be used as a US implementation document for the corresponding AAS3P. The AAS3Ps allow for tailoring of the test programs. In this case, if required, the JOTP would address nation specific tailoring that would meet or exceed the requirements in the AAS3P.

The JOTP may be developed in advance of the corresponding AAS3P development. In this case, the JOTP may be reissued after development of the AAS3P if international cooperation revealed technical superiority."

21

JMST Standardization Approach

JOTPs

TOPs

ITOPs

STANAGs

and AAS3Ps

AAS3P – Allied Ammunition Safety and Suitability for Service Publication DSPO – Defense Standardization Program Office DTC – Developmental Test Center ITOP – International Test Operation Procedure MIL-STD – Military Standard STANAG – Standardization Agreement TOP – Test Operation Procedure

MIL-STDs

22

JMST Standardization Process

Identify Need or discrepancy

Standard Exists

Modify Existing

Standard

Sufficient for Joint

Use

Use Existing Standard

INTL applicability

Develop Standard

(National WG)

Develop Standard

(INTL WG)

Urgent National Need?

Publish National (JOTP/Mil-Std)

Publish National (JOTP/Mil-Std)

Publish ISA

Publish National (JOTP/Mil-Std)

Revise Existing Standard

YES

YES

YES

YES

YES

NO

NO

NO

NO NO

JOTP – Joint Ordnance Test Procedure Mil-Std – Military Standard INTL – International ISA – International Standardization Agreement WG – Working Group

Create New Standard

Flow point sequence is based upon the need identified

23

JMST Safety Test Development Methodology Develop Joint standardized munition safety tests by commodity grouping for all

acquisition programs involved in developing weapons systems and for all sponsors involved in developing system-specific capabilities documents (CDD/CPDs).

Conduct initial analysis and detailed comparisons for purpose, applicability, item configuration, preconditioning requirements, conditions, pass/fail criteria, sample size.

Pre-Workshop activity captures common testing objectives, documents duplicative testing and validates technical rationale for any differences.

Conduct Workshops to resolve issues and create working draft test document by key Subject Matter Experts (SME).

Post-Workshop activity builds on consensus, is characterized by full transparency and collaboration, and expands the participation of stakeholders to the broader test community.

Documents are formatted and produced in accordance with AAP-3J and S3AP (Safety and Suitability for Service Allied Publication) of STANAG 4629 for AC326 approval.

24

AC/326-SG-B S3 WG

Document Divisions

Philosophy of Test

STANAG 4297 – AOP15 STANAG 4629 – Overarching S3 AP

Missile/Rocket (MR) 10-Series

Air Launched (MR-AL)

Surface and Underwater Launched (MR-SUL)

Shoulder Launched (MR-SL)

Guidance (G)

Single Environment (G-SE)

Glossary (G-G)

IM (IM)

E3 (E3)

Software (SW)

Munition Specific

Vulnerabilities

Support

Ammunition (A) 20-Series

Large Caliber (A-LC)

Sm Caliber (A-SC)

Non-Lethal (A-NL)

Med. Caliber(A-MC)

Man Emplaced Demolition (A-MC)

Explosive Ancillary (D) 30 Series

Man Carried Ancillary (D-M)

Aircraft Non-stores (D-A)

Explosive Ancillary – Navy (D-N)

Mortars (A-M)

Taxonomy for Drafting JMST Documents

25

AAS3P-10 (Analytical) Initial Inspection

7.1

Munition Hazard Classification Testing

9.1 (TBD)

Lightning Hazard (live) (1) H1-3.0b

Solar Radiation (52) C1-5.0

Logistic Drop Test(3) C2-1.3

Level I (Basic) Inspection

7.2

Level II (Intermediate)

Inspection7.3

Level III (Full ) Inspection/BTCA

7.4 / Annex E

Other Safety TestsH7

(ambient) (cold)

Insensitive Munitions Assessment Testing

9.2 (TBD)

AUR Level Firing Tests

(10) D1

Component Tests

(24) D2

See Detailed Flow Chart

Climatic Tests and BTCA(8) C1

INSPECTION LEGEND

Quantity from Hot Flow

Quantity from Cold Flow

XX-X.X = procedure reference (Annex/Appendix-Paragraph)

9 day High Temperature Storage (26) C1-3.0

28 day High Temperature Cycle (52) C1-4.0

Low Temperature Storage (52) C1-2.0

Temperature Shock (52) C1-6.0

FLOW CHART LEGEND

Temperature Determined by Test Requirement

(inert non-sequential tests and assessments)

(live sequential tests)

Warhead Arena (4) H4

(52)

(live non-sequential tests and assessments)

Humid Heat (52) C1-1.0 HERO

H1-1.0

ESDH1-2.0

Lightning Hazard (inert) H1-3.0c

Firing Circuits9.4

Weapon Danger Area Analysis(based on AUR Firing data)

D1-1c

Health Hazard Assessment(based on AUR Firing data)

H2

Operational & MaintenanceH3

Software Safety Assessment9.3

Mould Growth/Contamination by Fluids

H6

Hot

Unpackaged Transit Drop(13) C2-3.0

Tactical Land Transport Dynamics(26) C2-2.0

(13)

(13)Common Carrier

Vibration (26)C2-1.1

(10)

(xx)

Packaged Transit Drop (13) C2-1.2

(4)

(12)

Air Transport Dynamics (26) C2-5.0

Cold

Packaged Transit Drop (13) C2-1.2

(12)

(10)

Common Carrier Vibration (26)

C2-1.1

Unpackaged Transit Drop (13) C2-3.0

Tactical Land Transport Dynamics(26) C2-2.0

(13)

(13)

(4)(xx)

Air Transport Dynamics (26) C2-5.0

Shipboard UNDEX Shock(Safe for Disposal)

(1) C2-4.0

E3 Tests 9.6 / H1(may contain EED’s/ESAD’s)

Amb

AUR Level Firing Tests

(10) D1

Example: AAS3P-10 General S3 Test Flow for Shoulder Launched Munitions (Analytical)

26

Example: AAS3P-12 General S3 Test Flow for Aircraft Launched Munitions (Analytical)

BTCA – Breakdown Test and Criticality Analysis/ Level III Examination

27

Example: AAS3P-20 General S3 Test Flow for Large Caliber Naval Munitions (Analytical)

28

AAS3P-10 (Tailoring) S3 Working Group tailors test series to commodity item when developing the JOTPs

Program tailors test program to projected commodity life cycle – Tailoring shall be approved by National S3 Authority

Test Asset requirements are tailored – Tailoring shall be approved by National S3 Authority

Example Annex B, Appendix 3 of AAS3P-10, “An S3 test program is to be conducted for a previously fielded system with a new propulsion unit. The modifications include new propellant charge weight and new igniter, but structural and sealing components remain unchanged. Warhead, guidance, and seeker systems are unchanged, as is the anticipated user environment. The warhead safe and arm/fuze component(s) have been qualified (or has a favorable S3 assessment) in accordance with AOP-20.”

Example uses the analytical approach and reduces the sample size from 52 down to 22 (additional rounds required for Insensitive Munitions, Hazard Classification, Electromagnetic Environmental Effects, and logistical drop).

AAS3P – Three Aspects of Tailoring:

29

JOTP-001 National Safety and Suitability for Service (S3) US DoD Authorities

The following service contacts are responsible for the assessment of munitions safety:

Joint National Authority – Joint Weapons Safety Working Group (JWSWG) Army - Army Safety Office Navy/Marine Corps - (for weapon safety): Commanding Officer Naval Ordnance Safety & Security Activity, N3 Navy/Marine Corps - (for IM): Commanding Officer Naval Ordnance Safety & Security Activity, N85 Air Force - (for weapon safety): AFSA/SEWV, Kirtland AFB Air Force - (for IM): ASC/YOX, Eglin AFB

30

10 series: Missiles & Rockets

20 series:

Ammunition

30 series:

“Others”

AAS3P-1: Guidance

AAS3P-10: Shoulder launched man portable rockets and missiles

AAS3P-11: Surface and underwater launched missiles and rockets

AAS3P-12: Aircraft launched munitions

AAS3P-20: Large Caliber munitions

AAS3P-21: Medium Caliber munitions

AAS3P-30: Aircraft non-stores

AAS3P-31: Ship carried ancillary munitions

AAS3P-32: Surface

AAS3P-33: Man carried ancillary munitions

S3 Documents

AAS3P-23: Mortars

AAS3P-22: Small Caliber munitions

31

On average, one JMST doc replaces 3 existing standards. For example, STANAG 4629, AAS3P-1, and Ammunition (A) Series Replaces:

4224 Ed 4 AAS3P-20 Large Calibre Artillery and Naval Gun Munitions Greater than 40mm, Safety and Suitability for Service Evaluation

4493 Ed 1 AAS3P-20 Tank Ammunition Safety and Suitability for Service Assessment

4517 AAS3P-20 Large Calibre Ordnance Greater Than 40mm, Design Safety Requirements and Safety and Suitability for Service Evaluation of Weapon/Munition Interface

4667 Ed 1 AAS3P-20 Gun Launched Guided Munitions

4423 Ed 2 AAS3P-21 Cannon Ammunition (12.7 to 40 mm) - Safety and Suitability for Service Evaluation.

4516 AAS3P-21 Cannon (above 12.7) Design Safety Requirements and Safety and Suitability for Service Evaluations of Weapon/Munition Interface

4608 Ed 1 AAS3P-22 Ammunition Below 12.7 mm calibre – Design Safety Requirements and S3 Evaluations

4225 Ed 2 AAS3P-23 The Safety Evaluation of Mortar Bombs

4433 Ed 1 AAS3P-23 Field Mortar Munitions, Design Safety Requirements

4520 AAS3P-2x Rifle Launched Grenades, Design Safety Requirements and S3 Evaluation

4599 Ed 1 AAS3P-2x Weapon Launched Grenades – Design Safety Requirements and S3 Evaluations

STANAG

32

For example, Missile/Rocket (MR) Series Replaces:

4337 Ed 1 AAS3P-11 Surface-Launched Munitions, Appraisal Safety and Environmental Tests

3786 Ed 4 AAS3P-12 Safety Design Requirements for Airborne Dispenser Weapons

4325 Ed 2 AAS3P-12 Environmental and Safety Tests for the Appraisal of Air Launched Munitions

4432 Ed 1 AAS3P-12 Air-Launched Guided Munitions, Principles for Safe Design

4333 Ed 1 AAS3P-11 Underwater Munitions, Principles for Safe Design

4338 Ed 1 AAS3P-11 Underwater-Launched Munitions, Safety Evaluation

STANAG

33

Table of Contents

Origins, Goals and Scope of JMST

Process

Accomplishments

Applications and Opportunities

34

JMST docs Posted to ASSIST, from 2011 to present

35

Other JMST Documents in Development:

JOTP- 62 Electrostatic Discharge/Precipitation Static

JOTP-23 – Mortars

JOTP/AAS3P-11 – Surface and Underwater-Launched Munitions

JOTP/AAS3P-22 – Small Caliber Ammunition

JMST POA&M

Aug 2014

Year

Month J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J

Surface Launched and Underwater-Launched Munitions

JOTP-62 ESD/P-Static

JOTP-23 MortarsJOTP/AP-22 Small Caliber Ammo

JOTP/AP-11

JOTP/AP-21 Med Cal MunitionsJOTP/AP-30 Aircraft Non-stores

JOTP/AP-31 Ship Carried Ancillary

JOTP/AP-32 FuzesJOTP/AP-33 Man Carried Ancillary

JOTP-E3 Lightning

AP-23 Mortars

JOTP-AP-10 Shoulder Launched Revision

2014 2015 2016 2017

Con

fere

nces

/ W

orks

hops

Mun

ition

s S

afet

y D

ocum

ents

JOTP- ESD/PESD

Definitions of Terms:AP - Allied PublicationEEE - Electromagnetic Environmental EffectsESD - Electrostatic DischargeFESWG - Fuze Engineering Standardization Working GroupHHHA - Human Health Hazards AssessmentJOTP - Joint Ordnance Test ProcedureP-Static - Precipitation Static

Note: Document timelines include a 3-month approval cycle.

JOTP- Mortars Workshop

36

37

JMST Points of Contact:

Ken Thompson Aberdeen Test Center Tel: (443) 861-9338 DSN 848 Email: kenneth.p.thompson14.civ@mail.mil

Jim Gerber Naval Ordnance Safety and Security Activity Code N31 - Weapon System Safety / WSESRB Tel: (301) 744-6018 DSN 354-6018 Email: james.gerber1@navy.mil SIPR: james.gerber1@navy.smil.mil

38

Table of Contents

Origins, Goals and Scope of JMST

Process

Accomplishments

Applications and Opportunities

39

JOTP Process is transferrable and scalable: Other Applications

These functional communities have used the established JOTP approval process to address a shortfall/established need:

Fuze Engineering Standardization Working Group – JOTP-050 Design Requirements for Active Hazard Mitigation Devices – JOTP-051 Technical Manual for the Use of Logic Devices in Safety

Features – JOTP-052 Guideline for the Qualification of Fuzes, Safe and Arm (S&A)

Devices, and Ignition Safety Devices (ISD)

Explosive Ordnance Disposal – JOTP-070 Identification Marking for Munitions

40

Avoids Re-testing

Increases Acceptability of Test Data

Reduces Asset Quantity Required for Test: ‘Interchangeability’

Saves Program Time +

$$$

JOTP for Your Process…

41

Backup

42

JWSWG

JMST AAS3P/JOTP Approval and Implementation Process

AAS3P

Yes

JOTP

No

Service SMEs draft

JOTP/AAS3P document

Service JMST Champion (SES level) provides adjudication of critical comments, if needed

Coordinate via ASSIST for intra-

service agreement (includes JWSWG

concurrence)

AAS3P or JOTP?

AC326 Main Group for approval under STANAG 4620 *

AT&L/ S&TS/ LW&M

Director approves?

DSPO: signed JOTPs and AAS3Ps are published to

ASSIST

Program Managers follow

JOTP/AAS3P

* During a recent AC326 SG/B meeting at NATO, Reps from the NATO Standardization Office provided clarification on AAP-3J which has had an impact on the coordination and ratification of the AAS3Ps. We now have to produce a covering STANAG for all AAS3P documents. This will add time to the ratification and promulgation process.