Critical Design Review

50.1 General.
The CDR shall be conducted on each configuration item prior to fabrication/production/coding release to insure that the detail design solutions, as reflected in the Draft Hardware Product Specification, Software Detailed Design Document (SDDD), Data Base Design Document(s) (DBDD(s)), Interface Design Document(s) (IDD(s)), and engineering drawings satisfy requirements established by the hardware Development Specification and Software Top Level Design Document (STLDD). CDR shall be held after the Computer Software Operator's Manual (CSOM), Software User's Manual (SUM), Computer System Diagnostic Manual (CSDM), Software Programmer's Manual (SPM), and Firmware Support Manual (FSM) have been updated or newly released. For complex/large configuration items the CDR may be conducted on an incremental basis, i.e., progressive reviews are conducted versus a single CDR. The overall technical program risks associated with each configuration item shall also be reviewed on a technical (design and manufacturing), cost and schedule basis. For software, a technical understanding shall be reached on the validity and the degree of completeness of the SDDD, IDD(s), DBDD(s), STD, CRISD, SPM, and FSM, and preliminary versions of the CSOM, SUM, and CSDM.

50.1.1 Equipment/Facilities configuration items.
The detail design as disclosed by the hardware Product Specification, drawings, schematics, mockups, etc., shall be reviewed against the HWCI Development Specification performance requirements. For other than facilities, the result of a successful CDR shall be the establishment of the design baseline for detailed fabrication/production planning i.e., the contractor is permitted to use the detail design as presented at CDR and reflected in the hardware Product Specification for planning for production and, if specifically authorized, for initial fabrication/production efforts.

50.1.2 Computer Software configuration items (CSCIs).
The CDR for a CSCI shall be a formal technical review of the CSCI detail design, including data base and interfaces. The CDR is normally accomplished for the purpose of establishing integrity of computer software design at the level of a Unit's logical design prior to coding and testing. CDR may be accomplished at a single review meeting or in increments during the development process corresponding to periods at which components or groups of components reach the completion of logical design. The primary product of the CDR is a formal identification of specific software documentation which will be released for coding and testing. By mutual agreement between the contractor and the contracting agency, CDRs may be scheduled concurrently for two or more CSCIs.

50.1.2.1 Since computer software development is an iterative process, the completion of a CDR for a CSCI is not necessarily sufficient for maintaining adequate visibility into the remaining development effort through testing.

50.1.2.2 Additional In-Progress Reviews may be scheduled post- CDR which address:

? a. Response to outstanding action items

? b. Modifications to design necessitated by approved ECPs or design/program errors

? c. Updating sizing and timing data

? d. Updated design information, as applicable

? e. Results obtained during in-house testing, including problems encountered and solutions implemented or proposed.

50.2 Items to be Reviewed. The contractor shall present the following for review by the contracting agency:

50.2.1 HWCIs

? a. Adequacy of the detail design reflected in the draft hardware Product Specification in satisfying the requirements of the HWCI Development Specification for the item being reviewed.

? b. Detail engineering drawings for the HWCI including schematic diagrams.

? c. Adequacy of the detailed design in the following areas:

1. (1) Electrical design

2. (2) Mechanical design

3. (3) Environmental control and thermal aspects

4. (4) Electromagnetic compatibility

5. (5) Power generation and grounding

6. (6) Electrical and mechanical interface compatibility

7. (7) Mass properties

8. (8) Reliability/Maintainability/Availability

9. (9) System Safety Engineering

10. (10) Security Engineering

11. (11) Survivability/Vulnerability (including nuclear)

12. (12) Producibility and Manufacturing

13. (13) Transportability, Packaging and handling

14. (14) Human Engineering and Biomedical Requirements (including Life Support and Crew Station Requirements)

15. (15) Standardization

16. (16) Design versus Logistics Trade-offs

17. (17) Support equipment requirements

? d. Interface control drawings

? e. Mock-ups, breadboards, and/or prototype hardware

? f. Design analysis and test data

? g. System Allocation Document for HWCI inclusion at each scheduled location.

? h. Initial Manufacturing Readiness (for example, manufacturing engineering, tooling demonstrations, development and proofing of new materials, processes, methods, tooling, test equipment, procedures, reduction of manufacturing risks to acceptable levels).

? i. Preliminary VECPs and/or formal VECPs

? j. Life cycle costs

? k. Detail design information on all firmware to be provided with the system.

? l. Verify corrosion prevention/control considerations to insure materials have been chosen that will be compatible with operating environment.

? m. Findings/Status of Quality Assurance Program

50.2.2 CSCIs.

? a. Software Detailed Design, Data Base Design, and Interface Design Document(s). In cases where the CDR is conducted in increments, complete documents to support that increment shall be available.

? b. Supporting documentation describing results of analyses, testing, etc., as mutually agreed by the contracting agency and the contractor.

? c. System Allocation Document for CSCI inclusion at each scheduled location.

? d. Computer Resources Integrated Support Document.

? e. Software Programmer's Manual

? f. Firmware Support Manual

? g. Progress on activities required by CSCI PDR (para 40.2.2).

? h. Updated operation and support documents (CSOM, SUM, CSDM).

? i. Schedules for remaining milestones.

? j. Updates since the last review to all previously delivered software related CDRL items.

50.2.3 Support Equipment (SE):

? a. Review requirements (paragraphs 50.2.1 and 50.2.2) for SE.

? b. Verify maximum considerations GFE SE

? c. Identify existing or potential SE provisioning problems

? d. Determine qualitative and quantitative adequacy of provisioning drawings and data

? e. Review reliability of SE

? f. Review logistic support requirements for SE items

? g. Review Calibration requirements

? h. Review documentation for SE.

50.2.4. Engineering Data.
Continuing from the results of the Preliminary Design Review (PDR), review engineering data as defined in para 3.15, as to suitability for intended use. The review should consider the checklist items discussed in para 100.6, as properly tailored.

50.3 Detailed Evaluation of Electrical, Mechanical, and Logical Designs.

50.3.1 HWCIs. Detailed block diagrams, schematics, and logic diagrams shall be compared with interface control drawings to determine system compatibility. Analytical and available test data shall be reviewed to insure the hardware Development Specification has been satisfied.

50.3.1.1 The contractor shall provide information on firmware which is included in commercially available equipment or to be included in equipment developed under the contract. Firmware in this context includes the microprocessor and associated sequence of micro-instructions necessary to perform the allocated tasks. As a minimum, the information presented during CDR shall provide descriptions and status for the following:

? a. Detailed logic flow diagrams

? b. Processing algorithms

? c. Circuit diagrams

? d. Clock and timing data (e.g., timing charts for micro- instructions)

? e. Memory (e.g., type (RAM, PROM), word length, size (total and spare capacity))

? f. Micro-instruction list and format

? g. Device functional instruction set obtained by implementation of firmware.

? h. Input/output data width (i.e., number of bits for data and control.)

? i. Self-test (diagnostics) within firmware.

? j. Support software for firmware development:

1. (1) Resident assembler

2. (2) Loader

3. (3) Debugging routines

4. (4) Executive (monitor)

5. (5) Non-resident diagnostics

6. (6) Cross assembler and higher level language on host computer

1. (7) Instruction simulator

50.3.2 CSCIs.
The contractor shall present the detailed design (including rationale) of the CSCI to include:

? a. The assignment of CSCI requirements to specific Lower- Level Software Units, the criteria and design rules used to accomplish this assignment, and the traceability of Unit and LLSU designs to satisfy CSCI requirements, with emphasis on the necessity and sufficiency of the Units for implementing TLSU design requirements.

? b. The overall information flow between software Units, the method(s) by which each Unit gains control, and the sequencing of Units relative to each other.

? c. The design details of the CSCI, TLSUs, LLSUs, and Units including data definitions, timing and sizing, data and storage requirements and allocations.

? d. The detailed design characteristics of all interfaces, including their data source, destination, interface name and interrelationships; and, if applicable, the design for direct memory access. The contractor shall also give an overview of the key design issues of the interface software design, and indicate whether data flow formats are fixed or subject to extensive dynamic changes.

? e. The detailed characteristics of the data base. Data base structure and detailed design, including all files, records, fields, and items. Access rules, how file sharing will be controlled, procedures for data base recovery/ regeneration from a system failure, rules for data base manipulation, rules for maintaining file integrity, rules for usage reporting, and rules governing the types and depth of access shall be defined. Data management rules and algorithms for implementing them shall be described. Details of the language required by the user to access the data base shall also be described.

50.4 Electromagnetic Compatibility.

? a. Review contractor EMC design of all HWCIs. Determine compliance with requirements of the Electromagnetic Compatibility Plan and HWCI specifications.

? b. Review system EMC including effects on the electromagnetic environment (inter-system EMC) and intra- system EMC. Determine acceptability of EMC design and progress toward meeting contractual EMC requirements.

? c. Review EMC test plans. Determine adequacy to confirm EMC design characteristics of the system/HWCI/subsystem.

50.5 Design Reliability.

50.5.1 Review the most recent predictions of hardware and software reliability and compare against requirements specified in hardware Development Specification and Software Requirements Specification. For hardware, predictions are substantiated by review of parts application stress data.

50.5.2 Review applications of parts or configuration items with minimum life, or those which require special consideration to insure their effect on system performance is minimized.

50.5.3 Review completed Reliability Design Review Checklist to insure principles have been satisfactorily reflected in the configuration item design.

50.5.4 Review applications of redundant configuration item elements or components to establish that expectations have materialized since the PDR.

50.5.5 Review detailed HWCI reliability demonstration plan for compatibility with specified test requirements. The number of test articles, schedules, locations, test conditions, and personnel involved are reviewed to insure a mutual understanding of the plan and to provide overall planning information to activities concerned.

50.5.6 Review the failure data reporting procedures and methods for determination of failure trends.

50.5.7 Review the thermal analysis of components, printed circuit cards, modules, etc. Determine if these data are used in performing the detailed reliability stress predictions.

50.5.8 Review on-line diagnostic programs, off-line diagnostic programs, support equipment, and preliminary technical orders (and/or commercial manuals) for compliance with the system maintenance concept and specification requirements.

50.5.9 Review software reliability prediction model and its updates based upon test data and refined predictions of component usage rates and complexity factors.

50.6 Design Maintainability.

50.6.1 Review the most recent predictions of quantitative maintainability and compare these against requirements specified in the HWCI Development Specification and Software Requirements Specification.

50.6.2 Review preventive maintenance frequencies and durations for compatibility with overall system requirements and planning criteria.

50.6.3 Identify unique maintenance procedures required for the configuration item during operational use and evaluate their total effects on system maintenance concepts. Assure that system is optimized from a maintenance and maintainability viewpoint and conforms with the planned maintenance concept. This shall include a review of provisions for automatic, semi- automatic, and manual recovery from hardware/software failures and malfunctions.

50.6.4 Identify design-for-maintainability criteria provided by the checklist in the design detail to insure that criteria have, in fact been incorporated.

50.6.5 Determine if parts, assemblies, and other items are so placed that there is sufficient space to use test probes, soldering irons, and other tools without difficulty and that they are placed so that structural members of units do not prevent access to them or their ease of removal.

50.6.6 Review detailed maintainability demonstration plan for compatibility with specified test requirements. Supplemental information is provided and reviewed to insure a mutual understanding of the plan and to provide overall planning information to activities concerned.

50.7 Human Factors.

50.7.1 Review detail design presented on drawings, schematics, mockups, or actual hardware to determine that it meets human performance requirements of the HWCI Development Specification and Software Requirements Specification. Interface Requirements Specification(s), and accepted human engineering practices.

50.7.2 Demonstrate by checklist or other formal means the adequacy of design for human performance.

50.7.3 Review each facet of design for man/machine compatibility. Review time/cost/effectiveness considerations and forced trade-offs of human engineering design.

50.7.4 Evaluate the following human engineering/biomedical design factors:

? a. Operator controls

? b. Operator displays

? c. Maintenance features

? d. Anthropometry

? e. Safety features and emergency equipment

? f. Work space layout

? g. Internal environmental conditions (noise, lighting, ventilation, etc.)

? h. Training equipment

? i. Personnel accommodations

50.8 System Safety.

50.8.1 Review configuration item detail design for compliance to safety design requirements.

50.8.2 Review acceptance test requirements to insure adequate safety requirements are reflected therein.

50.8.3 Evaluate adequacy of detailed design for safety and protective equipment/devices.

50.8.4 Review configuration item operational maintenance safety analyses and procedures.

50.9 Natural Environment.

50.9.1 Review detail design to determine that it meets natural environment requirements of the hardware Development Specification.

50.9.2 Insure that studies have been accomplished concerning effects of the natural environment on, or interactions with, the HWCI. Studies which have been in progress shall be complete at this time.

50.9.3 Determine whether arrangements have been made to obtain current and/or forecast natural environment information, when needed for certain HWCIs. Assure compatibility of HWCI and source of information by comparing electrical characteristics and formats for the source and the HWCI.

50.10 Equipment and Parts Standardization.

50.10.1 Equipment and Components.
Determine that every reasonable action has been taken to fulfil the standardization requirements for use of standard items (standard item with NSN should be first preference) and to obtain approval for use of non-standard or non-preferred items. Accordingly, the following criteria shall be evaluated:

? a. Data sources that were reviewed.

? b. Factors that were considered in the decision to reject known similar, existing designs.

? c. Factors that were considered in decisions to accept any existing designs which were incorporated, and the trade- offs, if any, that had to be made.

50.10.2 Parts

? a. Determine whether there are any outstanding non- standard or non-preferred parts approval requests and action necessary for approval or disapproval. (Status of parts control program operations).

? b. Identify non-standard-non-preferred parts approval problems and status of actions toward resolving the problems.

? c. Review potential fabrication/production line delays due to non-availability of standard or preferred parts. In such cases, determine whether it is planned to request use of parts which may be replaced by standard items during subsequent support repair cycles. Assure that appropriate documentation makes note of these items and that standard replacement items shall be provisioned for support and used for repair.

? d. Require certification that maximum practical inter- changeability of parts exists among components, assemblies, and HWCIs. Reservations concerning interchangeability are identified, particularly for hardness critical items.

? e. Sample preliminary drawings and cross check to insure that parts indicated on the drawings are compatible with the Program Parts Selection List.

50.10.3 Assignment of Official Nomenclature.

? a. Determine whether official nomenclature and approval of nameplates have been obtained to extent practical.

? b. Determine whether DD Form 61, Request for Nomenclature, has been processed to the agreed level of indenture.

? c. Insure that approved nomenclature has been reflected in the Development and Product Specifications.

? d. Identify problems associated with nomenclature requests (DD-61s) together with status of actions towards resolving the problems.

? e. Insure that a software inventory numbering system has been agreed to and implemented to the CSCI level.

50.11 Value Engineering (VE).

50.11.1 Review status of all VECPs presented per the terms of the contract.

50.11.2 Review any new areas of potential Value Engineering considered profitable to challenge.

50.11.3 If required by contract (funded VE program), review the actual Value Engineering accomplishments against the planned VE program.

50.12 Transportability.

50.12.1 Review transportability evaluations accomplished for those items identified as outsized, overweight, sensitive, and/or requiring special temperature and humidity controls.

50.12.2 Review actions taken as a result of the above evaluation to insure adequate facilities and military or commercial transporting equipment are available to support system requirements during Production and Deployment Phases.

50.12.3 Review design of special materials handling equipment, when required, and action taken to acquire equipment.

50.12.4 Insure DOD Certificates of Essentiality for movement of equipment have been obtained for equipment exceeding limitations of criteria established in contract requirements.

50.12.5 Insure transportability approval has been annotated on design documents and shall remain as long as no design changes are made that modify significant transportability parameters.

50.12.6 Identify equipment to be test loaded for air transportability of material in Military Aircraft.

50.13 Test.

50.13.1 Review updating changes to all specifications subsequent to the PDR, to determine whether Section 4.0 of the specifications adequately reflects these changes.

50.13.2 Review all available test documentation for currency, technical adequacy, and compatibility with Section 4.0 of all Specification requirements.

50.13.3 For any development model, prototype, etc., on which testing may have been performed, examine test results for design compliance with hardware Development, Software Requirements, and Interface Requirements Specification requirements.

50.13.4 Review quality assurance provisions/qualification requirements in HWCI Product, Software Requirements, or Interface Requirements Specifications for completeness and technical adequacy. Section 4.0 of these specifications shall include the minimum requirements that the item, materiel, or process must meet to be acceptable.

50.13.5 Review all test documentation required to support test requirements of Section 4.0 of HWCI Product Specifications for compatibility, technical adequacy, and completeness.

50.13.6 Inspect any breadboards, mockups, or prototype hardware available for test program implications.

50.13.7 Review Software Test Descriptions to ensure they are consistent with the Software Test Plan and they thoroughly identify necessary parameters and prerequisites to enable execution of each planned software test and monitoring of test results. As a minimum, test descriptions shall identify the following for each test:

? a. Required preset hardware and software conditions and the necessary input data, including the source for all data.

? b. Criteria for evaluating test results.

? c. Prerequisite conditions to be established or set prior to test execution.

? d. Expected or predicted test results.

50.14 Maintenance and Maintenance Data.

50.14.1 Review adequacy of maintenance plans.

50.14.2 Review status of unresolved maintenance and maintenance data problems since the PDR.

50.14.3 Review status of compliance with Data Item titled "Reliability, Maintainability Data Reporting and Feedback Failure Summary Reports."

50.15 Spare Parts and Government Furnished Property (GFP).

50.15.1 Review provisioning planning through normal logistics channels and Administrative Contracting Officer (ACO) representative (Industrial Specialist) to insure its compatibility (content and time phasing) with contractual requirements (data and SOW items). The end objective is to provision by a method which shall insure system supportability at operational date of the first site. Also accomplish the following:

? a. Insure contractor understanding of contractual requirements, including time phasing, instructions from logistics support agencies, interim release authority and procedure, and responsibility to deliver spare/repair parts by need date.

? b. Determine that scheduled provisioning actions, such as, guidance meetings, interim release and screening, are being accomplished adequately and on time.

? c. Identify existing or potential provisioning problems.

50.15.2 Determine quantitative and qualitative adequacy of provisioning drawings and data. Verify that Logistics Critical items are listed for consideration and that adequate procedures exist for reflecting design change information in provisioning documentation and Technical Orders.

50.15.3 Insure support requirements have been determined for installation, checkout, and test for approval by contracting agency. Insure screening has been accomplished and results are included into support requirements lists.

50.15.4 Determine that adequate storage space requirements have been programmed for on-site handling of Installation and Checkout (I&C), test support material, and a scheme has been developed for "down streaming" and joint use of insurance (high cost) or catastrophic failure support items.

50.15.5 Assure that Acquisition Method Coding (AMC) is considered.

50.16 Packaging/SDPE.

50.16.1 Review proposed package design to insure that adequate protection to the HWCI, and the media on which the CSCI is recorded, is provided against natural and induced environments/ hazards to which the equipment will be subjected throughout its life cycle, and to insure compliance with contractual requirements. Such analysis shall include, but not be limited to, the following:

? a. Methods of preservation

? b. Physical/mechanical/shock protection including cushioning media, shock mounting and isolation features, load factors, support pads, cushioning devices, blocking and bracing, etc.

? c. Mounting facilities and securing/hold-down provisions

? d. Interior and exterior container designs.

? e. Handling provisions and compatibility with aircraft materials handling system (463L)

? f. Container marking

? g. Consideration and identification of dangerous/hazardous commodities

50.16.2 Review design of SDPE HWCI to determine if a category I container is required. The analysis of the proposed container or handling, shipping equivalent shall encompass as a minimum:

? a. Location and type of internal mounting or attaching provisions

? b. Vibration - shock isolation features, based on the pre-determined fragility rating (or other constraint of the item to be shipped.)

? c. Service items (indicators, relief valves, etc.)

? d. Environmental control features

? e. External handling, stacking and tie-down provisions with stress ratings.

? f. Dimensional and weight data (gross and net)

? g. Bill-of-material

? h. Marking provisions including the center-of-gravity location

? i. For wheeled SDPE (self-powered or tractor/trailer) the overall length, width, and height with mounted item, turning radius, mobility, number of axles, unit contact load, number of tires, etc.

o j. Position and travel of adjustable wheels, titling, or other adjustments to facilitate loading.

50.16.3 Review the results of trade studies, engineering analyses, etc., to substantiate selected package/SDPE design approach, choice of materials, handling provisions, environmental features, etc.

50.16.4 Insure that package/SDPE design provides reasonable balance between cost and desired performance.

50.16.5 Review all preproduction test results of the prototype package design to insure that the HWCI is afforded the proper degree of protection.

50.16.6 Review Section 5, Packaging, of the HWCI Product Specification for correct format, accuracy and technical adequacy.

50.16.7 Review contractor procedures to assure that the requirements of Section 5, Preparation for Delivery of the approved HWCI Product Specification, will be incorporated into the package design data for provisioned spares.

50.17 System Allocation Document.

50.17.1 Review maintenance of the System Allocation Document since PDR.

50.17.2 Insure plans are initiated for configuration item re-allocations that may be necessary due to actions occurring prior to, or during, CDR.

50.18Design Producibility and Manufacturing.

50.18.1 Review the status of all producibility (and productivity) efforts for cost and schedule considerations.

50.18.2 Review the status of efforts to resolve manufacturing concerns identified in previous technical reviews and their cost and schedule impact to the production program.

50.18.3 Review the status of Manufacturing Technology programs and other previously recommended actions to reduce cost, manufacturing risk and industrial base concerns.

50.18.4 Identify open manufacturing concerns that require additional direction/effort to minimize risk to the production program.

50.18.5 Review the status of manufacturing engineering efforts, tooling and test equipment demonstrations, proofing of new materials, processes, methods, and special tooling/test equipment.

50.18.6 Review the intended manufacturing management system and organization for the production program in order to show how their efforts will effect a smooth transition into production.

50.19 Post Review Action.

50.19.1 After completing the CDR, the contractor shall publish and distribute copies of Review minutes. The contracting agency officially acknowledges completion of a CDR as indicated in paragraph 4.2.4.

50.19.2 The accomplishment of the CDR shall be recorded on the configuration item Development Record by the contractor.

APPENDIX F

Date: 2016-06-13; view: 18