Navigating DLA First Article Testing (FAT): Compliance and Operational Risk

First Article Testing (FAT) is a critical quality assurance hurdle in many Defense Logistics Agency (DLA) contracts, particularly for complex components or new suppliers. It is the process of testing the first production run to ensure the manufacturer can meet all technical requirements before full-scale production begins.

The Purpose of FAT

The primary goal of FAT is to minimize risk for the Department of Defense. By verifying the manufacturing process early, DLA ensures that large quantities of non-conforming parts are not produced and delivered. For the contractor, successfully passing FAT is often a prerequisite for progress payments and the authorization to ship the remainder of the order.

Managing Operational Risk during FAT

Contractors often underestimate the time and cost associated with First Article Testing. To manage this risk, consider the following:

• Timeline Integration: FAT can take weeks or months. Ensure your production schedule accounts for the time required for testing, government witness requirements (if applicable), and final approval by the DLA contracting officer.
• Test Facilities: Determine if the testing must be performed at a government laboratory or an approved independent third-party lab. If it is contractor-performed, ensure your quality personnel are familiar with the specific MIL-STD test protocols.
• Documentation: Precision in reporting is mandatory. Every dimension, material property, and performance metric must be documented in a comprehensive FAT report (often using DI-NDTI-80809 or similar Data Item Descriptions).

Government vs. Contractor FAT

Read your contract carefully to determine who is responsible for the testing (Contractor Testing vs. Government Testing). If the contract specifies Government First Article Testing, you will likely be required to ship the test units to a specific DLA facility and await their verification before proceeding.