MIL-HDBK-781 Revision A:1996
Current
The latest, up-to-date edition.
RELIABILITY TEST METHODS, PLANS, AND ENVIRONMENTS FOR ENGINEERING DEVELOPMENT, QUALIFICATION AND PRODUCTION
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1 Scope
1.1 Purpose
1.2 Applicability
1.2.1 Application of handbook
1.3 Method of references
1.4 Equipment categories
2 Applicable documents
2.1 General
2.2.1 Specifications, standards, and handbooks
2.3 Non-government publications
2.4 Order of precedence
3 Definitions
3.1 Terms
3.1.1 Corrective maintenance (repair)
3.1.2 Decision risks
3.1.3 Multiple failures
3.1.4 Measures of reliability
3.1.5 Mission profile
3.1.6 Life-cycle profile
4 Reliability test methods and test plans
4.1 Reliability test program
4.2 Integrated reliability test planning
4.3 Environmental test conditions
4.4 Test instrumentation and facilities
4.5 Performance baselines
4.6 Failure reporting, analysis and correction action
system
4.7 Failure categories
5 Recommended combined environmental test conditions
5.1 Purpose
5.2 Test planning
5.3 Test methods
5.4 Test methods and test plan selection factors
5.5 Reliability development/growth evaluation methods
5.6 Durability/economic life test
5.7 ESS monitoring methods
5.8 MTBF assurance test
5.9 Sequential test plans
5.10 Fixed-duration tests
5.11 All-equipment production reliability acceptance
test plan
5.12 Reliability estimates from unit-level results
6 Test instrumentation and facilities
6.1 Purpose
6.2 Thermal and vibration survey
6.3 Mission and life-cycle environmental profiles
and test conditions
6.4 Combined environments for fixed-ground equipment
6.5 Combined environments for mobile ground equipment
6.6 Combined environments for shipboard and underwater
vehicle equipments
6.7 Combined environments for jet aircraft equipment
6.8 Combined environments for V/STOL equipment
6.9 Combined environments for turbopropellor aircraft
and helicopter equipment
6.10 Combined environments for air-launched weapons and
assembled external stores
6.11 Missile transportation, handling and storage
7 Test instrumentation and facilities
7.1 Purpose
7.2 Test facilities and apparatus
8 Notes
8.1 Intended use
8.2 Supersession
8.3 Subject term (keyword) listing
8.4 Changes from previous issue
NUMEROUS TABLES
NUMEROUS FIGURES
Provides for reliability testing during development, qualification, and production of systems and equipment. Coverage includes: reliability test methods and test plans; combined environmental test conditions; test instrumentation and facilities. Also gives definitions, reference documents, tables and diagrams.
| Committee |
AREA SESS
|
| DevelopmentNote |
Supersedes MIL STD 781. A NOTICE 1 - Notice of Validation. (02/2015)
|
| DocumentType |
Standard
|
| Pages |
412
|
| PublisherName |
US Military Specs/Standards/Handbooks
|
| Status |
Current
|
| Supersedes |
| MIL-PRF-49316 Revision A:1997 | TEST SET, ELECTRONIC SYSTEMS, TS-3895A/UV |
| MIL-R-29583 Base Document:1992 | RADIO SET |
| MIL PRF 62542 : B | BALL SCREW LINEAR ACTUATOR (BSLA) |
| MIL-PRF-32080 Revision G:2014 | TRUCK, AIRCRAFT FUELING-DEFUELING, 6,000 GALLON, A/S32R-11 |
| GEIA TA HB 0009 : 2013 | RELIABILITY PROGRAM HANDBOOK |
| DEFSTAN 00-035(PT3)/5(2017) : 2017 | ENVIRONMENTAL HANDBOOK FOR DEFENCE MATERIEL - PART 3: ENVIRONMENTAL TEST METHODS |
| MIL-DTL-49198 Revision B:2014 | HEADSET-MICROPHONE KIT, MK-1564( )/AIC |
| MIL-I-25863 Revision D:1990 | INDICATOR, ELECTRICAL TACHOMETER 0-110 PERCENT RPM, 2-INCH SIZE, INTEGRALLY LIGHTED |
| MIL P 24765 : 0 | POWER SUPPLY, UNINTERRUPTIBLE, STATIC |
| MIL P 49146 : B | POWER SUPPLY 18 MILLIMETER, MICROCHANNEL WAFER |
| MIL-DTL-27188 Revision C:2006 | INDICATOR, PRESSURE EGU-2/A, OIL, 0-100 PSI |
| MIL-DTL-19803 Revision G:2007 | CONVERTER, LIQUID OXYGEN, 10-LITER, GCU-24A/A |
| MIL-STD-750-3 Base Document:2012 | Transistor Electrical Test Methods for Semiconductor Devices Part 3: Test Methods 3000 Through 3999 |
| MIL-T-83823 Base Document:1991 | TRUCK, FIRE FIGHTING (STRUCTURAL OR BRUSH STRUCTURAL) |
| MIL-PRF-83419 Revision F:2016 | ALTIMETER, SERVO CONTROLLED, AUTOMATIC PRESSURE STANDBY |
| MIL-DTL-25949 Revision F:1995 | ACCELEROMETER, AIRCRAFT RANGE -5 TO 10G UNITS, INTEGRALLY LIGHTED |
| MIL-STD-883 Revision K:2016 | TEST METHOD STANDARD - MICROCIRCUITS |
| BS EN 50155:2017 | Railway applications. Rolling stock. Electronic equipment |
| 16/30282633 DC : 0 | BS EN 50155 - RAILWAY APPLICATIONS - ELECTRONIC EQUIPMENT USED ON ROLLING STOCK |
| EN 61124:2012 | RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY (IEC 61124:2012) |
| DEFSTAN 00-970(PT0)/9(2012) : 2012 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| MIL-DTL-24151 Revision B:2016 | DOORS, ROLLER CURTAIN AND HINGED SLAT, AND ASSOCIATED OPERATING EQUIPMENT |
| DEFSTAN 00-970(PT0)/17(2016) : 2016 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/14(2014) : 2014 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/7(2011) : 2011 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/15(2015) : 2015 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/12(2014) : 2014 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/13(2014) : 2014 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/11(2013) : 2013 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/8(2011) : 2011 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| MIL-DTL-5099 Revision C:2011 | INDICATOR, CABIN AIR PRESSURE, 1-7/8 INCH DIAL, TYPE MA-1 |
| DEFSTAN 00-970(PT0)/10(2013) : 2013 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| DEFSTAN 00-970(PT0)/16(2015) : 2015 | DESIGN AND AIRWORTHINESS REQUIREMENTS FOR SERVICE AIRCRAFT - PART 0: PROCEDURES FOR USE, CONTENT AND DEFINITIONS |
| MIL-DTL-6162 Revision C:2000 | GENERATORS AND STARTER-GENERATORS, ELECTRICAL DIRECT CURRENT, NOMINAL 30 VOLTS, AIRCRAFT GENERAL SPECIFICATION FOR |
| MIL-P-49452 Base Document:1989 | POWER SUPPLY 18 MM, MICROCHANNEL WAFER, GEN III, MX-10130()/UV |
| MIL-E-29581 Base Document:1991 | EARCUP, UNIT ACTIVE NOISE REDUCTION SYSTEM |
| MIL-DTL-25867 Revision D:2006 | GAGE, PRESSURE, DIAL INDICATING, PNEUMATIC |
| MIL-PRF-49404 Revision A:1997 | Bias Voltage Regulator, CN-1559/UA (No S/S Document) |
| MIL-DTL-24765 Revision B:2016 | POWER SUPPLY, UNINTERRUPTIBLE, STATIC (NAVAL SHIPBOARD) |
| MIL-PRF-49434 Revision A:1997 | AIMING LIGHT, INFRARED, AN/PAQ-4C |
| MIL-A-24233 Revision B:1989 | ANTENNA, AS-1735( )/SRC |
| IEEE 1332-2012 | IEEE Standard Reliability Program for the Development and Production of Electronic Products |
| MIL-F-51536 Base Document:1988 | FILTER UNIT, GAS-PARTICULATE, 200 CFM, 208V, 400 HZ, M56 |
| MIL-PRF-49177 Revision B:1997 | SCAN-INTERLACE, PL-1408/UA |
| MIL-DTL-38195 Revision D:2000 | Generator Set, Gas Turbine Engine, 60 KW 400 Hertz, General Purpose |
| MIL-DTL-52872 Revision D:1998 | Sensor Group, Ultrasonic Motion: Transceiver RT-1161/FSS-9(V) and Processor MX-9444/FSS-9(V) |
| MIL-F-24713 Base Document:1989 | FREQUENCY CHANGER, STATIC, AIR COOLED (NAVAL SHIPBOARD) |
| DEFSTAN 00-42(PT7)/1(2014) : 2014 | RELIABILITY AND MAINTAINABILITY - PART 7: RELIABILITY TESTING |
| MIL-DTL-25469 Revision J:2014 | Valves, Filler, Liquid Oxygen, Aircraft Type |
| SAE ARP 81490 : 2016 | TRANSMISSION LINES, TRANSVERSE ELECTROMAGNETIC MODE |
| SAE ARP 94910 : 2012 | AEROSPACE - VEHICLE MANAGEMENT SYSTEMS - FLIGHT CONTROL DESIGN, INSTALLATION AND TEST OF, MILITARY UNMANNED AIRCRAFT, SPECIFICATION GUIDE FOR |
| I.S. EN 50155:2017-11 | RAILWAY APPLICATIONS - ROLLING STOCK - ELECTRONIC EQUIPMENT |
| MIL-HDBK-115 Revision C:2016 | U.S. ARMY REVERSE ENGINEERING HANDBOOK (GUIDELINES AND PROCEDURES) |
| MIL-PRF-38230 Revision D:2008 | TRANSMITTER, PRESSURE, OIL, VARIABLE RELUCTANCE |
| MIL-DTL-52876 Revision D:1997 | Cabinets, Monitor, CY-7359/FSS-9(V), CY-7360/FSS-9(V) and CY-7361/FSS-9(V) |
| MIL-A-28865 Revision A:1987 | ANTENNA GROUP, OE-82()/WSC-1(V) |
| MIL-PRF-26139 Revision E:2015 | TESTER, PRESSURIZED CABIN LEAKAGE, AIRCRAFT, (AF/M24T-3 AND AF/M32T-1) |
| IEEE 1633-2016 REDLINE | IEEE Recommended Practice on Software Reliability |
| MIL-HDBK-338 Revision B:1998 | ELECTRONIC RELIABILITY DESIGN HANDBOOK |
| MIL-DTL-16392 Revision D:2015 | BRAKE, ELECTRO-MECHANICAL, NAVAL SHIPBOARD |
| MIL-PRF-49293 Revision B:2011 | RADIAC SET, AN/PDR-75 |
| MIL-PRF-49168 Revision C:1997 | SCAN-INTERLACE, PL-1403/UA, PL-1403A/UA |
| ABS 0272 : 2017 | GUIDANCE NOTES ON QUALIFYING NEW TECHNOLOGIES |
| DEFSTAN 00-41/3(1993) : 1993 | RELIABILITY AND MAINTAINABILITY MOD GUIDE TO PRACTICES AND PROCEDURES |
| MIL-DTL-25308 Revision C:2010 | GAGE, PRESSURE, DIAL INDICATING, HYDRAULIC, TYPE ME-1 |
| SAE AS 19692 : 2016 | Aerospace – Military Type Variable Delivery, Pressure Compensated Hydraulic Pump |
| SAE AIR 1277 : 2005 | COOLING OF MILITARY AVIONIC EQUIPMENT |
| IEC TR 62866:2014 | Electrochemical migration in printed wiring boards and assemblies - Mechanisms and testing |
| MIL-STD-750-1 Revision A:2015 | Environmental Test Methods for Semiconductor Devices Part 1: Test Methods 1000 Through 1999 |
| EN 50155:2017 | Railway applications - Rolling stock - Electronic equipment |
| MIL-HDBK-344 Revision A:1993 | ENVIRONMENTAL STRESS SCREENING (ESS) OF ELECTRONIC EQUIPMENT |
| MIL-DTL-38394 Revision E:2009 | Transmitter, Pressure TRU-81/A, Oil, 0-500 PSI |
| MIL-PRF-49163 Revision B:1997 | VIDEO PREAMPLIFIER, AM-6923/UA |
| MIL-HDBK-2164 Revision A:1996 | ENVIRONMENTAL STRESS SCREENING PROCESS FOR ELECTRONIC EQUIPMENT |
| MIL-PRF-49318 Revision A:1997 | Test Set, Electronic Systems, TS-4348/UV |
| UNE-EN 61124:2014 | Reliability testing - Compliance tests for constant failure rate and constant failure intensity |
| DEFSTAN 00-35(PT3)/4(2006) : 2006 | ENVIRONMENTAL HANDBOOK FOR DEFENCE MATERIEL - PART 3: ENVIRONMENTAL TEST METHODS |
| CEI EN 61124 : 2013 | RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY |
| MIL-DTL-5882 Revision E:2013 | TRANSMITTER, PRESSURE, MULTIPURPOSE, 0-50 PSI, MS28005-1 |
| DEFSTAN 00-40(PT7)/1(2003) : 2003 | RELIABILITY AND MAINTAINABILITY (R&M) - PART 7: (ARMP-7) NATO R&M TERMINOLOGY APPLICABLE TO ARMP'S |
| MIL-DTL-5790 Revision H:2008 | Transmitter, Pressure, Oil, Synchro, 0-200 PSI 320-Degree Movement, 26V, Single Phase, 400 Cycles |
| MIL-A-52879 Revision C:1992 | Alarm, Audible, BZ-204/FSS-9(V) (No S/S Document) |
| MIL-DTL-7627 Revision G:2010 | INDICATOR, TURN AND SLIP, 28 V DC |
| MIL-DTL-52869 Revision C:1997 | Sensor Group, Passive Ultrasonic: Receiver R-1860/FSS-9(V) and Processor MX-9443/FSS-9(V) |
| ADS-63-SP : 2001 | AERONAUTICAL DESIGN STANDARD - STANDARD PRACTICE - RADAR SYSTEM AIRWORTHINESS QUALIFICATION AND VERIFICATION REQUIREMENTS |
| MIL-PRF-49185 Revision B:1997 | RADIO SET AN/GRC-103(V)3 |
| RE.AERO 70306 : 2001 | GUIDELINES FOR RELIABILITY GROWTH CONTROL |
| MIL-PRF-52955 Revision D:2009 | IMPROVED POSITION AND AZIMUTH DETERMINING SYSTEM (IPADS) |
| MIL F 51544 : A | FILTER UNIT, GAS-PARTICULATE, 200 CFM, 208 VAC, M84 |
| MIL-A-0083216 Revision C:1976 | AIR CONDITIONER, HORIZONTAL, 54,000 BTUH, 208/230 V |
| MIL-DTL-27189 Revision E:2008 | INDICATOR, PRESSURE, OIL |
| I.S. EN 61124:2012 | RELIABILITY TESTING - COMPLIANCE TESTS FOR CONSTANT FAILURE RATE AND CONSTANT FAILURE INTENSITY |
| SAE AS 94900 : 2007 | AEROSPACE - FLIGHT CONTROL SYSTEMS - DESIGN, INSTALLATION AND TEST OF PILOTED MILITARY AIRCRAFT, GENERAL SPECIFICATION FOR |
| PD IEC/TR 62866:2014 | Electrochemical migration in printed wiring boards and assemblies. Mechanisms and testing |
| IEC 61124:2012 | Reliability testing - Compliance tests for constant failure rate and constant failure intensity |
| MIL-DTL-9398 Revision D:2007 | GENERATOR, TACHOMETER, TWO-POLE, HIGH TEMPERATURE, AIRCRAFT |
| ARMP-7 : 2008 | NATO R&M TERMINOLOGY APPLICABLE TO ARMPS |
| AECTP-400 : 2006 | MECHANICAL ENVIRONMENTAL TESTS |
| 10/30238858 DC : 0 | BS EN 62506 - METHODS FOR PRODUCT ACCELERATED TESTING |
| SAE ARP 6461 : 2013 | GUIDELINES FOR IMPLEMENTATION OF STRUCTURAL HEALTH MONITORING ON FIXED WING AIRCRAFT |
| MIL-A-53129 Base Document:1992 | ALARM-MONITOR GROUP OA-9431/FSS-9(V) |
| MIL-DTL-24347 Revision C:2015 | Monitor, Available Load, 60 and 400 Hertz, A.C., 1 Phase, Electrical Power (Naval Shipboard Use) |
| MIL B 62542 : A | BALL SCREW LINEAR ACTUATOR |
| MIL-P-49090 Revision D:1992 | POWER SUPPLY 25 MILLIMETER, MICROCHANNEL INVERTER |
| MIL-L-85314 Revision A:1983 | LIGHT SYSTEMS, AIRCRAFT, ANTI COLLISION, STROBE, GENERAL SPECIFICATION FOR |
| MIL-O-52374 Revision E:2013 | Oscillator: High Voltage General Specification for |
| MIL-T-23752 Revision E:1992 | TRITIUM AIR MONITOR, PORTABLE OR FIXED |
| ADS-65-HDBK : 2004 | AERONAUTICAL DESIGN STANDARD - HANDBOOK - AIRWORTHINESS QUALIFICATION AND VERIFICATION GUIDANCE FOR ELECTRO-OPTICAL AND SENSOR SYSTEMS |
| MIL-A-29521 Base Document:1988 | ANTENNA GROUP, AN/BRA-34(V), AN/BRA-34A(V), AN/BRA-34B(V) |
| MIL-C-85283 Revision B:1994 | CONTROL MONITOR SET, GUIDED WEAPON, AN/AWW-9 |
| MIL-DTL-27190 Revision C:2006 | INDICATOR, PRESSURE AGU-3/A, HYDRAULIC, 0-4,000 PSI |
| RE.AERO 70305 : A2000 | GUIDE FOR RELIABILITY CONTROL |
| MIL-STD-781 Revision D:1986 | RELIABILITY TESTING FOR ENGINEERING DEVELOPMENT, QUALIFICATION AND PRODUCTION |
| MIL T 49318 : 1991-11-21 | TEST SET, ELECTRONIC SYSTEMS |
| MIL-PRF-49320 Revision A:1997 | LASER INFRARED OBSERVATION SET, AN/PVS-6 |
| BS EN 61124:2012 | Reliability testing. Compliance tests for constant failure rate and constant failure intensity |
| MIL-HDBK-189 Revision C:2011 | RELIABILITY GROWTH MANAGEMENT |
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