MIL-STD-1798 Mechanical Equipment And Subsystems Integrity ProgramThe purpose of this standard is to describe the general process to achieve and maintain the physical and functional integrity of the mechanical elements of aircraft systems. The goal of this integrity program is to achieve the desired level of safety and aircraft availability at the most economic cost across the life cycle of the weapon system. This standard allows the process to be tailored in a competitive environment to meet specific equipment, subsystem, and/or system requirements. The Mechanical Equipment and Subsystems Integrity Program MECSIP is implemented in the planning process and continued until retirement of the system.

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MIL-STD-1798C

5.4.16  Maintainability/reparability demonstrations.

The contractor shall conduct a program to develop and demonstrate maintenance procedures. The demonstrations may be conducted in conjunction with development and/or full system tests. Authorized repairs and repair limits shall be in accordance with the documented maintenance and logistics requirements.  Testing will be conducted as required to validate the integrity of authorized repairs.

5.4.17  Acceptance Test Procedures.

Subsystem component Acceptance Test Procedures (ATP) shall be developed by the principle integration engineering authority. The approved acceptance test procedures shall be used to evaluate the performance of all new production and overhauled components.  New production part acceptance limits and overhauled component service limits shall be developed.

5.4.18  Evaluation and interpretation of ground test results.

The contractor shall describe the procedures to evaluate, interpret, and incorporate all test findings (e.g., cause, corrective actions, Program implications, maintenance projections, and costs).  This evaluation shall define corrective actions required to demonstrate design requirements are met.  Each problem (cracking, yielding, wear, leakage, etc.) that occurs during testing shall be evaluated.  Inspections, disassembly, and destructive tear-down evaluations shall be conducted.

5.4.19   Evaluation and interpretation of flight test results.

Thorough, instrumented flight tests shall be planned and conducted for each subsystem with at least one safety-critical function.  A careful review of the test results is critical to verify the system responds in the manner predicted by analysis as well as verification of specific performance and safety of flight requirements.  A build-up approach is typically used to safely conduct the flight test evaluations.  Following each build-up test point the data is evaluated to determine if the system is behaving as predicted by the analysis.  This approach allows detection of potential flight-safety critical anomalies before operating in the region of the flight envelop where those anomalies may present themselves.

5.4.20  Integrated test plan.

All test requirements identified for the specific sub-system equipment shall be defined, scoped, and scheduled in an integrated test package.  This includes tests associated with development and full qualification, as well as any subsequently-scheduled growth or margin testing.  Vendor and supplier tests shall be included in this test package. The contractor shall seek the most economical balance of requirements, verification, and test articles when integrated sub-system tests are compiled.  The integrated test packages shall be incorporated into the overall Test and Evaluation Master Plan (TEMP).

5.4.21  Final integrity analysis.

The design analyses (Task III) for safety-, mission-, and durability-critical components shall be updated to account for significant differences between analyses, tests, and the thermal/environmental/load survey. These updated analyses shall provide data on operational limits to be used in maintenance, inspection, and repair times for critical components. These analyses and evaluation of test results shall be utilized to develop maintenance and inspection planning.  Analyses to be updated shall include, but not be limited to, the following:

a.   durability;

b.   strength;

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