Army Rejects Call for Independent Assessments of Body Armor

BY Herschel Smith
14 years, 4 months ago

About eight months ago the GAO issued a report concerning body armor (SAPI plate) recall, and outlined a number of findings concerning the testing the Army had performed.  We summarized a few of the findings in DoD Testing Requirements for Body Armor and Army Recall.

COPD is “Contract Purchase Description,” PEO is “Program Executive Officer,” and BFD means “Back Face Deformation.”  This last concept becomes important in the overall picture.  Turning to the specifics of the report, several key findings are outlined below for the purpose of providing examples of the investigation.

The inconsistencies that we identified concerned the treatment of over velocity shots.  During first article testing conducted on February 20 and November 7, 2007, shots on six of the plates were over the required velocity. Because none of the shots resulted in a complete penetration, the shots should have been considered fair, and the test should have proceeded, according to the COPD. During the November 7, 2007, test, the testing facility official complied with the COPD and correctly proceeded with testing. However, even though the scenario was exactly the same for the February 20, 2007, test, the testing facility official conducted retests on additional plates. The testing facility official documented all of the shots, including the retests, and provided the test results to PEO Soldier for scoring.  When scoring the test results for the February 20, 2007, first article test (design M3D2S2), the PEO Soldier scoring official chose to use the test results for the retested plates when he computed the test score. Use of the retested plates resulted in a score of 5.5 points, and the contractor passed the first article test. Had the scoring official followed the fair shot acceptance criteria as stated in the COPD and used the initial plates that withstood the over velocity shot, the contractor would have accumulated an additional 1.5 points (complete penetration on the second shot) and would have failed the first article test with 7 points.

Translation: When an over-velocity shot is taken on a plate, the testing may proceed if the plate is not penetrated under the assumption that a lower velocity shot would not have penetrated either.  This is a reasonable assumption.  However, if the plate is penetrated by the second shot it fails the testing, even if weakened by the initial shot.  The PEO made the decision to exclude the plates that had sustained over-velocity shots on the initial testing and to perform retests, but not consistently (as later records show).  A second example of the Inspector General’s findings pertains to measurements of BFD (back face deformation).

PEO Soldier instructed the testing facility to deviate from the COPD and use an offset correction technique (a mathematical formula used to adjust the BFD) when measuring the BFD. The testing facility official used this technique during 2 of the 21 first article tests conducted under Contract 0040. The COPD required that the testing facility officials measure the BFD at the deepest point in the clay depression after the bullet impacted the plate. However, PEO Soldier officials stated that contractors complained that the BFD measurement was not fair if the deepest point in the clay was not behind the point of impact. Therefore, a PEO Soldier official instructed the testing facility in an April 25, 2005, e-mail to use the offset correction technique if the deepest point in the clay depression was not behind the bullet’s point of impact.

Translation: The contractors complained when the measurement of deepest penetration was made at any point other than the point of bullet impact, which is the point of highest risk to the Soldier.  Therefore, the PEO made a decision that a correction would be applied to account for this effect and bring consistency to the program.

The Captain’s Journal initially concurs with both of the program deviations discussed above, since it isn’t fair to penalize one plate as compared to another if an over-velocity shot happened to be taken against it, and also since the highest risk to the Soldier does happen to be the point of bullet impact.

And it is also fair to point out that these aren’t the only problems discussed in the report.  But there are deeper problems that discussed even in the report.  With respect to the over-velocity shots, our judgment is that not enough SAPI plates are being included in the test samples (i.e., the sample size is not large enough) and the boundary conditions (such as shot velocity) are not being well-managed.  With respect to the deformation, the question naturally arises why the most severe deformation is occurring anywhere other than the point of bullet impact?  What’s happening to the ESAPI plates that is causing deformation in other than impact locations?

These questions (and other such technical questions) are not posed or answered in the Inspector General’s report, since the investigation is done by a government office.  The investigation focuses on programs, QA, adherence to procedures, consistency of application of rules and the like.  True enough, there are problems with some of the above.

But Senators and Representatives who have infinite trust in the power of government to solve problems leave the technology to the experts when a government office is the the sole arbiter of the strength of any technical program – and technological expert doesn’t usually define government offices.  In this particular case, as we have suggested before, there is no shame in assistance from industry experts.

Questions have been raised above which point to the need for completely independent consultative services focusing on QA, programmatic controls, statistical analysis of sample size, control over testing boundary conditions, and most especially the SAPI plates themselves and the underlying fracture mechanics of bullet impacts by finite element analysis.

At this point the business of body armor investigations wasn’t complete at the Government Accountability Office.  Hence, in October 2009 they issued Warfighter Support: Independent Expert Assessment of Army Body Armor Test Results and Procedures Needed Before Fielding.  In the executive summary they state:

To determine what effect, if any, the problems GAO observed had on the test data and on the outcomes of First Article Testing, the Army should provide for an independent ballistics evaluation of the First Article Testing results by ballistics and statistical experts external to the Department of Defense before any armor is fielded to soldiers under this contract solicitation. Because DOD did not concur with this recommendation, GAO added a matter for congressional consideration to this report suggesting that Congress direct DOD to either conduct such an independent external review of these test results or repeat First Article Testing.

To better align actual test practices with established testing protocols during future body armor testing, the Army should assess the need to change its test procedures based on the outcome of the independent experts’ review and document these and all other key decisions made to clarify or change the testing protocols during future body armor testing. Although DOD did not agree that an independent expert review of test results was needed, DOD stated it will address protocol discrepancies identified by GAO as it develops standardized testing protocols. DOD also agreed to document all decisions made to clarify or change testing protocols.

To improve internal controls over the integrity and reliability of test data for future testing as well as provide for consistent test conditions and comparable data among tests, the Army should provide for an independent external peer review of Aberdeen Test Center’s body armor testing protocols, facilities, and instrumentation to ensure that proper internal controls and sound management practices are in place. DOD generally concurred with this recommendation, but stated that it will also include DOD members on the review team.

Consistent with our own recommendations, they counsel in the strongest possible terms that outside independent consultative support be obtained.  But as soon as the GAO released its report, the DoD released a statement claiming confidence in the safety of the SAPI plates – a completely irrelevant rejoinder to the overall recommendations of the GAO report to procure consultative support for the program.  The same day that the DoD announced that they had full confidence in their body armor tests, they announced several new QA positions concerning ballistics and body armor testing.

The Army is sounding defensive and unwilling to open their program to outside expert inspection and assessment.  Here at The Captain’s Journal we haven’t recommended draconian measures such as jettisoning the Army test program, or complete replacement of the SAPI (at least until an equivalent, lighter weight ballistic insert can be developed).  We have only recommended the engagement of outside consultative services for the Army, just as did the GAO.

For the Army to reject that recommendation is very small and in extremely bad form.  When counsel has been given to open your programs to outside inspection and that counsel is rejected, it constitutes poor engineering.  There are many industries which “live in a glass house,” so to speak: nuclear, commercial air transport, pharmaceutical and medical, just to mention a few.  There is no valid technical or budgetary reason whatsoever that the Army cannot open their program to inspection by people who know as much or more than they do.

Trackbacks & Pingbacks


Comments

RSS feed for comments on this post. TrackBack URL

Leave a comment


You are currently reading "Army Rejects Call for Independent Assessments of Body Armor", entry #4105 on The Captain's Journal.

This article is filed under the category(s) Army,Body Armor,Department of Defense and was published October 26th, 2009 by Herschel Smith.

If you're interested in what else the The Captain's Journal has to say, you might try thumbing through the archives and visiting the main index, or; perhaps you would like to learn more about TCJ.

26th MEU (10)
Abu Muqawama (12)
ACOG (2)
ACOGs (1)
Afghan National Army (36)
Afghan National Police (17)
Afghanistan (704)
Afghanistan SOFA (4)
Agriculture in COIN (3)
AGW (1)
Air Force (40)
Air Power (10)
al Qaeda (83)
Ali al-Sistani (1)
America (22)
Ammunition (275)
Animals (280)
Ansar al Sunna (15)
Anthropology (3)
Antonin Scalia (1)
AR-15s (372)
Arghandab River Valley (1)
Arlington Cemetery (2)
Army (86)
Assassinations (2)
Assault Weapon Ban (28)
Australian Army (7)
Azerbaijan (4)
Backpacking (2)
Badr Organization (8)
Baitullah Mehsud (21)
Basra (17)
BATFE (217)
Battle of Bari Alai (2)
Battle of Wanat (18)
Battle Space Weight (3)
Bin Laden (7)
Blogroll (3)
Blogs (24)
Body Armor (23)
Books (3)
Border War (18)
Brady Campaign (1)
Britain (38)
British Army (35)
Camping (5)
Canada (17)
Castle Doctrine (1)
Caucasus (6)
CENTCOM (7)
Center For a New American Security (8)
Charity (3)
China (16)
Christmas (16)
CIA (30)
Civilian National Security Force (3)
Col. Gian Gentile (9)
Combat Outposts (3)
Combat Video (2)
Concerned Citizens (6)
Constabulary Actions (3)
Coolness Factor (3)
COP Keating (4)
Corruption in COIN (4)
Council on Foreign Relations (1)
Counterinsurgency (218)
DADT (2)
David Rohde (1)
Defense Contractors (2)
Department of Defense (210)
Department of Homeland Security (26)
Disaster Preparedness (5)
Distributed Operations (5)
Dogs (15)
Donald Trump (27)
Drone Campaign (4)
EFV (3)
Egypt (12)
El Salvador (1)
Embassy Security (1)
Enemy Spotters (1)
Expeditionary Warfare (17)
F-22 (2)
F-35 (1)
Fallujah (17)
Far East (3)
Fathers and Sons (2)
Favorite (1)
Fazlullah (3)
FBI (39)
Featured (189)
Federal Firearms Laws (18)
Financing the Taliban (2)
Firearms (1,758)
Football (1)
Force Projection (35)
Force Protection (4)
Force Transformation (1)
Foreign Policy (27)
Fukushima Reactor Accident (6)
Ganjgal (1)
Garmsir (1)
general (15)
General Amos (1)
General James Mattis (1)
General McChrystal (44)
General McKiernan (6)
General Rodriguez (3)
General Suleimani (9)
Georgia (19)
GITMO (2)
Google (1)
Gulbuddin Hekmatyar (1)
Gun Control (1,630)
Guns (2,298)
Guns In National Parks (3)
Haditha Roundup (10)
Haiti (2)
HAMAS (7)
Haqqani Network (9)
Hate Mail (8)
Hekmatyar (1)
Heroism (4)
Hezbollah (12)
High Capacity Magazines (16)
High Value Targets (9)
Homecoming (1)
Homeland Security (3)
Horses (2)
Humor (72)
Hunting (31)
ICOS (1)
IEDs (7)
Immigration (104)
India (10)
Infantry (4)
Information Warfare (4)
Infrastructure (4)
Intelligence (23)
Intelligence Bulletin (6)
Iran (171)
Iraq (379)
Iraq SOFA (23)
Islamic Facism (64)
Islamists (98)
Israel (19)
Jaish al Mahdi (21)
Jalalabad (1)
Japan (3)
Jihadists (81)
John Nagl (5)
Joint Intelligence Centers (1)
JRTN (1)
Kabul (1)
Kajaki Dam (1)
Kamdesh (9)
Kandahar (12)
Karachi (7)
Kashmir (2)
Khost Province (1)
Khyber (11)
Knife Blogging (7)
Korea (4)
Korengal Valley (3)
Kunar Province (20)
Kurdistan (3)
Language in COIN (5)
Language in Statecraft (1)
Language Interpreters (2)
Lashkar-e-Taiba (2)
Law Enforcement (6)
Lawfare (14)
Leadership (6)
Lebanon (6)
Leon Panetta (2)
Let Them Fight (2)
Libya (14)
Lines of Effort (3)
Littoral Combat (8)
Logistics (50)
Long Guns (1)
Lt. Col. Allen West (2)
Marine Corps (280)
Marines in Bakwa (1)
Marines in Helmand (67)
Marjah (4)
MEDEVAC (2)
Media (67)
Medical (146)
Memorial Day (6)
Mexican Cartels (41)
Mexico (61)
Michael Yon (6)
Micromanaging the Military (7)
Middle East (1)
Military Blogging (26)
Military Contractors (5)
Military Equipment (25)
Militia (9)
Mitt Romney (3)
Monetary Policy (1)
Moqtada al Sadr (2)
Mosul (4)
Mountains (25)
MRAPs (1)
Mullah Baradar (1)
Mullah Fazlullah (1)
Mullah Omar (3)
Musa Qala (4)
Music (25)
Muslim Brotherhood (6)
Nation Building (2)
National Internet IDs (1)
National Rifle Association (95)
NATO (15)
Navy (30)
Navy Corpsman (1)
NCOs (3)
News (1)
NGOs (3)
Nicholas Schmidle (2)
Now Zad (19)
NSA (3)
NSA James L. Jones (6)
Nuclear (62)
Nuristan (8)
Obama Administration (221)
Offshore Balancing (1)
Operation Alljah (7)
Operation Khanjar (14)
Ossetia (7)
Pakistan (165)
Paktya Province (1)
Palestine (5)
Patriotism (7)
Patrolling (1)
Pech River Valley (11)
Personal (72)
Petraeus (14)
Pictures (1)
Piracy (13)
Pistol (4)
Pizzagate (21)
Police (647)
Police in COIN (3)
Policy (15)
Politics (969)
Poppy (2)
PPEs (1)
Prisons in Counterinsurgency (12)
Project Gunrunner (20)
PRTs (1)
Qatar (1)
Quadrennial Defense Review (2)
Quds Force (13)
Quetta Shura (1)
RAND (3)
Recommended Reading (14)
Refueling Tanker (1)
Religion (491)
Religion and Insurgency (19)
Reuters (1)
Rick Perry (4)
Rifles (1)
Roads (4)
Rolling Stone (1)
Ron Paul (1)
ROTC (1)
Rules of Engagement (75)
Rumsfeld (1)
Russia (37)
Sabbatical (1)
Sangin (1)
Saqlawiyah (1)
Satellite Patrols (2)
Saudi Arabia (4)
Scenes from Iraq (1)
Second Amendment (667)
Second Amendment Quick Hits (2)
Secretary Gates (9)
Sharia Law (3)
Shura Ittehad-ul-Mujahiden (1)
SIIC (2)
Sirajuddin Haqqani (1)
Small Wars (72)
Snipers (9)
Sniveling Lackeys (2)
Soft Power (4)
Somalia (8)
Sons of Afghanistan (1)
Sons of Iraq (2)
Special Forces (28)
Squad Rushes (1)
State Department (23)
Statistics (1)
Sunni Insurgency (10)
Support to Infantry Ratio (1)
Supreme Court (52)
Survival (185)
SWAT Raids (57)
Syria (38)
Tactical Drills (38)
Tactical Gear (14)
Taliban (168)
Taliban Massing of Forces (4)
Tarmiyah (1)
TBI (1)
Technology (21)
Tehrik-i-Taliban (78)
Terrain in Combat (1)
Terrorism (96)
Thanksgiving (13)
The Anbar Narrative (23)
The Art of War (5)
The Fallen (1)
The Long War (20)
The Surge (3)
The Wounded (13)
Thomas Barnett (1)
Transnational Insurgencies (5)
Tribes (5)
TSA (24)
TSA Ineptitude (13)
TTPs (4)
U.S. Border Patrol (6)
U.S. Border Security (18)
U.S. Sovereignty (23)
UAVs (2)
UBL (4)
Ukraine (10)
Uncategorized (98)
Universal Background Check (3)
Unrestricted Warfare (4)
USS Iwo Jima (2)
USS San Antonio (1)
Uzbekistan (1)
V-22 Osprey (4)
Veterans (3)
Vietnam (1)
War & Warfare (412)
War & Warfare (41)
War Movies (4)
War Reporting (21)
Wardak Province (1)
Warriors (6)
Waziristan (1)
Weapons and Tactics (79)
West Point (1)
Winter Operations (1)
Women in Combat (21)
WTF? (1)
Yemen (1)

March 2024
February 2024
January 2024
December 2023
November 2023
October 2023
September 2023
August 2023
July 2023
June 2023
May 2023
April 2023
March 2023
February 2023
January 2023
December 2022
November 2022
October 2022
September 2022
August 2022
July 2022
June 2022
May 2022
April 2022
March 2022
February 2022
January 2022
December 2021
November 2021
October 2021
September 2021
August 2021
July 2021
June 2021
May 2021
April 2021
March 2021
February 2021
January 2021
December 2020
November 2020
October 2020
September 2020
August 2020
July 2020
June 2020
May 2020
April 2020
March 2020
February 2020
January 2020
December 2019
November 2019
October 2019
September 2019
August 2019
July 2019
June 2019
May 2019
April 2019
March 2019
February 2019
January 2019
December 2018
November 2018
October 2018
September 2018
August 2018
July 2018
June 2018
May 2018
April 2018
March 2018
February 2018
January 2018
December 2017
November 2017
October 2017
September 2017
August 2017
July 2017
June 2017
May 2017
April 2017
March 2017
February 2017
January 2017
December 2016
November 2016
October 2016
September 2016
August 2016
July 2016
June 2016
May 2016
April 2016
March 2016
February 2016
January 2016
December 2015
November 2015
October 2015
September 2015
August 2015
July 2015
June 2015
May 2015
April 2015
March 2015
February 2015
January 2015
December 2014
November 2014
October 2014
September 2014
August 2014
July 2014
June 2014
May 2014
April 2014
March 2014
February 2014
January 2014
December 2013
November 2013
October 2013
September 2013
August 2013
July 2013
June 2013
May 2013
April 2013
March 2013
February 2013
January 2013
December 2012
November 2012
October 2012
September 2012
August 2012
July 2012
June 2012
May 2012
April 2012
March 2012
February 2012
January 2012
December 2011
November 2011
October 2011
September 2011
August 2011
July 2011
June 2011
May 2011
April 2011
March 2011
February 2011
January 2011
December 2010
November 2010
October 2010
September 2010
August 2010
July 2010
June 2010
May 2010
April 2010
March 2010
February 2010
January 2010
December 2009
November 2009
October 2009
September 2009
August 2009
July 2009
June 2009
May 2009
April 2009
March 2009
February 2009
January 2009
December 2008
November 2008
October 2008
September 2008
August 2008
July 2008
June 2008
May 2008
April 2008
March 2008
February 2008
January 2008
December 2007
November 2007
October 2007
September 2007
August 2007
July 2007
June 2007
May 2007
April 2007
March 2007
February 2007
January 2007
December 2006
November 2006
October 2006
September 2006
August 2006
July 2006
June 2006
May 2006

about · archives · contact · register

Copyright © 2006-2024 Captain's Journal. All rights reserved.