GOVERNMENT - INDUSTRY DATA EXCHANGE PROGRAM ALERT15-5, 15-97, 17-8, 19-11 & 25-29. 2 Grommet (Phase 2) 351-2954-000 351-2958-000 & -110; 351-2959-000. 351-2965-000. 351-2976-000. ITT

Distribution is not authorized outside of the GIDEP participant’s organization.

Please refer to the complete distribution policy at the GIDEP member’s website.

GOVERNMENT - INDUSTRY DATA EXCHANGE PROGRAM

ALERT

1. TITLE (Class, Function, Type, etc.) 2. DOCUMENT NUMBER

PE2-A-17-07 ITT Cannon to MIL-DTL-38999 "KJB" Series Ill Next Generation, Class F & W 3. DATE (DD-MMM-YY)

12-JUN-174. MANUFACTURER AND ADDRESS 5. PART NUMBER 6. NATIONAL STOCK NUMBER

ITT Cannon, LLC D38999/20*; D38999/24*, D38999/26* Not Available 56 Technology Drive 7. SPECIFICATION 8. GOVERNMENT PART NUMBER

Irvine, CA 92618 MIL-DTL-38999 D38999/20*; D38999/24*, D38999/26* 9. LOT DATE CODE START 10. LOT DATE CODE END

2008 Present 11. MANUFACTURER’S POINT OF CONTACT 12. CAGE 13. MANUFACTURER'S FAX

Michael Savage 71468 (714) 628-236914. MFR. POC PHONE 15. MANUFACTURER’S E-MAIL

(714) 628-2329 [email protected] 16. SUPPLIER 17. SUPPLIER ADDRESS 18. SUPPLIER CAGE

Not Applicable Not Applicable Not Applicable 19. PROBLEM DESCRIPTION / DISCUSSION / EFFECT

ITT Cannon (ITT) is not current on MIL-DTL 38999 retention of qualification testing. For the period 2012 to present, ITT observed the following test failures during retention of qualification testing:

• Visual and mechanical examination: requirements para 3.1, test method para 4.5.1• Durability- broken EMI spring: requirements para. 3.12, test method para. 4.5.8• Humidity- equipment malfunction: requirements para. 3.30, test method para. 4.5.26• Cavity-to-cavity air leakage: requirements para. 3.48, test method para. 4.5.44• Durability- excessive cycles: requirements para. 3.12, test method para. 4.5.8

In 2013 ITT requested approval from DLA to perform Qualification testing to allow ITT to use two outside processing plating houses. A Form 19P was submitted and approved by DLA to conduct this testing to a test plan contained in the Form 19P. During this testing, the following test failure was generated due to problems experienced during testing.

• Sine vibration test, accessory thread damage: requirements para. 3.27, test method para. 4.5.23.2.1

ITT is also reporting on this GIDEP certain changes in process, material, construction, sourcing or design incorporated in the construction of MIL-SPEC connectors for the period 2008 to present.

Block 19 continued on page 2.

20. ACTION TAKEN/PLANNED

DLA has imposed a stop production and stop shipment on ITT Cannon {ITT) and its Category C {Value-Added) Distributors relative to the subject MIL-SPEC. In addition, DLA has required that ITT disclose instances of using unapproved or nonconforming materials in the construction of the subject MIL-SPEC products for the period 2008 to present. Further GIDEP notifications beyond this one will be issued if additional non-conformances are identified.

21. DATE MFR. NOTIFIED/ SUPPLIER NOTIFIED

22. MFR./SUPPLIER RESPONSE 23. ORIGINATOR ADDRESS/POINT OF CONTACT

REPLY ATTACHED Michael Savage, ITT Cannon, LLC Not Applicable Not Applicable 56 Technology Drive

NO REPLY Irvine, CA 92618 [email protected] (714) 628-2329

24. GIDEP REPRESENTATIVE 25. SIGNATURE 26. DATE

Michael Regola Signature on File 12-JUN-17

GIDEP Form 97-1 (September 2009)

Block 19 Continued:

Retention of Qualification and Initial Qualification Testing

One test problem occurred during 24-month retention of qualification testing of this specification and product for the 24-month period ending February 2013. The test problem is summarized below:

1. Visual and mechanical examinationRequirements para. 3.1, test method para. 4.5.1

Retention of qualification testing for KJB requires connectors to be visually inspected and prepared prior to testing. ITT observed that wires with crimped contacts would not insert and lock into two cavities on part KJB6T23F21SN (Sample 1-3P), date code 1326-082, so the connector could not be used for this test.

The sample was replaced and testing continued, and there were no issues with the replacement sample.

Risk Assessment • This test problem was the result of an error in the test set-up that is not attributable to the connector sample.• The replacement sample passed contact retention testing.

******************

Three test problems occurred during 24-month retention of qualification testing of this specification and product for the 24-month period ending February 2015. The test problems are summarized below:

2. Durability – broken EMI springRequirements para. 3.12, test method para. 4.5.8

ITT observed that several sections of the EMI spring were broken off or bent out of shape during durability testing on Sample 1-3P. Based on further analysis, ITT identified that the EMI clip was not located in the correct place and started to peel up andoff during durability testing.

The following corrective actions were implemented: • A new EMI spring press was introduced on the assembly process• Monthly audits were performed on the assembly process to validate that each workstation was operated by trained

personnel.• A magnification lamp was implemented.• A new process was documented on MCI 25-11.• Personnel were trained on the MCI 25-11 new assembly method.• Personnel were certified on MCI 25-11, which covered CTQ for EMI spring assembly.• Personnel were certified on MCI 27-11 on the engaging and disengaging durability test.• PFMEA 002 was updated to document the failure mode and actions implemented.• QCI 3607 was modified to reflect 100% visual inspection for EMI spring assembly.

New samples were made and retested and these samples passed all retesting requirements.

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Risk Assessment • This is an assembly issue, which should be resolved through implementation of the above corrective actions.• If this test problem presented itself in the field, it would be observable by an end-user visually and when attempting

to mate the connector. This product may not mate and unmate for the full 500 test cycles. Once mated thisconnector will operate at full functionality.

• All inventory available on stock for PN 419-XXXX-XXX was segregated and validated 100% per the condition.• Since 2014, ITT is not aware of field failures attributed to this issue.

3. Humidity – equipment malfunctionRequirements para. 3.30, test method para. 4.5.26

ITT observed that the Thermotron chamber reached only -1.7°C even though the throttle was wide open to attain a lower temperature. Based on further analysis, ITT identified that the Thermotron chamber was programmed to attain -10°C and maintain high humidity, which it is incapable of doing. ITT determined that the root cause of the problem was test operator error and that the Thermotron was improperly programmed.

The Thermotron was subsequently reprogrammed so that humidity was not controlled while attaining and maintaining -10°C. The final cycle of the 10-day humidity test was rerun, and the IR and DWV measurements were taken again.

All connectors passed the retesting requirements.

Risk Assessment • This was a test set-up issue, not a product failure.

4. Cavity-to-cavity air leakageRequirements para. 3.48, test method para. 4.5.44

In GIDEP PE2-P-16-01 initially released on January 21, 2016 and as further amended, ITT reported failures in the cavity-to-cavity leakage bonding integrity test. The corrective actions and risk assessment related to this failure is fully set forth in the referenced GIDEP.

******************

I. Initial Qualification Testing

ITT completed initial qualification of ITT Cannon KJB product per MIL-STD-38999L, Amendment 1 for Class F, G and W in 2011. ITT provided data and test reports associated with all testing and any known failures to the qualifying activity as part of the qualification process. No fielded product is affected by any failures associated with this initial qualification.

II. Retention of Qualification Testing Currently in Progress

1. Durability – excessive cycles:Requirements para. 3.12, test method para. 4.5.8

During durability testing, 1 connector received 1,500 cycles of durability instead of the required 500 cycles. The excessive cycles were caused by an equipment malfunction. Specifically, the durability unit cycled the connector pair 1,500 times instead of 500. The error could not be duplicated.

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Risk Assessment • This test problem was the result of an error in the test set-up that is not attributable to the connector sample.• The replacement sample passed contact retention testing.

III. MIL-DTL-38999 Off-Site Non-ITT Plating

1. Sine vibration test, accessory thread damage:Requirements para. 3.27, test method para. 4.5.23.2.1

• During the sine vibration testing the backshells damaged the connector threads. This was a part plated by adomestic supplier.

The thread damage was caused by faulty back shells held on by a single set screw that came loose during vibration and wore the threads off. No one was monitoring testing progress, and the continued vibration in this loose condition appears to have broken several of the wires at the pin/socket crimp. Also, the brass back shell may have been heavier than needed according to the test, when the weight of the cable bundle is taken into account.

The failure has nothing to do with the new plating which is what was ultimately being tested here or the connector itself. The plating on the connector everywhere except where the back shell failed was in good condition. Since the part ran for the full sign test with no signs of plating degradation, retest is not needed.

Risk Assessment • This test problem was the result of poorly designed accessory weights added to existing backshells. It is not

attributable to the connector sample plating.

******************

Changes in process, materials, construction, sourcing or design

ITT is reporting in Appendix B of this GIDEP certain changes in process, material, construction, sourcing or design in the construction of MIL-SPEC connectors for the period 2008 to present.

******************

Summary of Field Failures and Corrective Actions

ITT is reporting in Appendix C of this GIDEP field failures for the period from 2008 to the present.

Page 4

APPENDIX A LOT DATE CODE START and LOT DATE CODE END

Retention of Qualification Testing

2) Durability – broken EMI springRequirements para. 3.12, test method para. 4.5.8

• Government Part Number: D38999/26* (ITT product with White elastomers)• Lot Date Code Start: 1321• Lot Date Code End: 1528

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APPENDIX B Changes in process, materials, construction, sourcing or design

ITT is also reporting on this GIDEP the following changes in process, material, construction, sourcing or design in the construction of MIL-SPEC connectors for the period 2008 to present.

1. Supply Source Changes - Unless otherwise noted, ITT has not been able to locatedocumentation confirming that it notified DLA Land and Maritime of these changes before theywere implemented. It is important to note however, that any source change made by ITT goesthrough a first article inspection (inclusive of material certification) prior to being used inproduction.

Item Material Type Material Supplier Location Description of Change

1 Insulator, Pin & Socket Front

(Phase 2)

144-2954-100 & -110144-2958-100 & -110144-2959-100 & -110144-2965-100 & -110144-2976-100 & -110

Domestic In 2014, ITT launched 5 new layouts for their KJB product that were listed on the QPL. The new insulator tooling was launched with a supplier that was not part of the initial supply chain. Layouts 15-5, 15-97, 17-8, 19-11 & 25-29.

2 Grommet (Phase 2)

351-2954-000351-2958-000 & -110

351-2959-000351-2965-000351-2976-000

ITT Cannon, Nogales In 2014, ITT launched 5 new layouts for their KJB product that were listed on the QPL. The new grommet tooling was launched at our Nogales facility, not part of the initial supply chain. Layouts 15-5, 15-97, 17-8, 19-11 & 25-29.

3 Plating All sizes Domestic ITT approved two domestic sources for plating shells after its internal plating line was shut down in 2015.

In 2014, ITT purchased plated parts from a domestic supplier (shells, barrels, coupling nuts). These purchases are not reflected in the supplier transaction data because they were purchased on a blanket purchase order.

2. Changes to Design, Process, or Materials - Unless otherwise noted, ITT has not been able tolocate documentation confirming that it notified DLA Land and Maritime of these changes beforethey were implemented.

Item Components Affected Year Description of Change

1 Tapout grommets 2011 Added cut to top of grommet due to interference from assembled component.

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I I I I


2 Shell, KJB7 (various sizes), master 2011 Removed excess datum callouts from various views and add datum [-x-] to drawings as it went missing between revisions.

3 38999 next gen jam nut shell assemblies

2011 Drawing error, double dimensioned.

4 38999 next gen barrel assemblies 2011 Deleted lubrication production step and added dimension for inspection.

5 Tapout insulator assemblies 2011 Changed drawing to clarify that 100% leak testing was not mandatory.

6 Insulator, front, pin, hard, KJB 2011 Opened tolerances and add a flatness and surface roughness callout to bonding surface to incorporate first article findings.

7 Insulator, front, SKT, hard, KJB 2011 Opened tolerances and add a flatness and surface roughness callout to bonding surface to incorporate first article findings.

8 Tapout 9-35 and 11-35 grommets 2011 Removed one alignment feature to fix a design error as the corresponding insulator did not have relief to accept it. When assembled this Interference was causing deformation of the surrounding cavities due to compression of the feature. Also added “Gate” reliefs in the lower “skirt” to clear mold gates in the corresponding insulator that it is bonded to.

9 Shell, master KJB0 various sizes 2011 Deleted note 6 which required a “polarization key” letter to be applied after plating for non-normal keying. This is not required per MIL-DTL-38999.

10 Shell, KJB7 (various sizes), master 2011 Deleted note 6 which required a “polarization key” letter to be applied after plating for non-normal keying. This is not required per MIL-DTL-38999.

11 Barrel, KJB6 (various sizes), master 2011 Eliminated stamp identification letter on barrel, parts will be gaged immediately prior to packaging.

12 Barrel Assy, KJB6, (various sizes), master

2011 Deleted note on drawing where parts were supposed to be marked with polarization letter on the hardware. Parts will be gaged immediately prior to packaging.

13 Shell Assy KJB7 (various sizes), master


14 Shell Assy KJB0 (various sizes), master


15 Tapout coupling nuts 2011 Removed individual GD&T tolerances on Diametric features in favor of the following note: All Diameters on the main C/L to be concentric.

16 Oven cure banding 2011 Changed manufacturing control instruction related to process improvement.

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17 Barrel Assy, KJB6-* 2011 Updated all BOM’s to standardize on a Nickel Plated EMI Spring for all Classes, F, G & W Barrel Assemblies.

18 KJB0-17 Shell 2011 Changed drawing to correct error. 19 Various KJB Tapout PLs 2011 Contact was purchased from a domestic supplier.

Reflected proper costing. 20 Tapout barrels 2012 Updated Insulator seating location control dimension

error to ensure proper insulator assembly location per Mil-Spec requirements and eliminated potential excess compression on the grommet due to an internal diameter step feature location.

21 Tapout square flange shells 2012 Eliminated possible interference with insulators.

22 Tapout jam nut shells 2012 Eliminated possible interference with insulators. Clarified D-shape flat dimension.

23 Connector, plug, KJB6 master; connector, RCPT, KJB0T Master;

connector, RCPT, KJB7

2013 Added Class J and M.

24 Insulator, front, SKT, hard & grommet, PIN/SKT,

(both) KJB 13-98 arr.

2012 Changed drawing to correct error and fixed tool.

25 Insulator rear PIN/SKT hard KJB 2012 Updated drawings per FAI and bring up requirements to supplier agreed standards.

26 Connector, recpt, PIN, elect,KJB7 11-35

2012 Change related to contact part number error on parts list calls out SKT contact S/B pin.

27 Electrical test DWV\IR 2013 Revised Manufacturing Control Instructions to improved fixture inspections prior to each new part number being tested to ensure fixture accuracy, compliance, missing/deformed components and performance. Testing requirements for electrical performance, based on layouts, were not changed.

28 Washer, clicker, plate, pressure KJB6-XX

2012 Production request to match tooling.

29 Spring, anti-VIB, KJB6-XX 2012 Production request to match tooling.

30 KJB size 23 and 25 rear insulators 2012 Changed related to too much force required in insert insulator stack into hardware.

31 Tapout interfacial seal keyway feature

2012 Added identification feature as visual aid for production.

32 KJB interfacial seals 2012 Changed drawing to correct errors/omissions.

33 Pin interfacial seals 2012 Changed drawing to correct errors/omissions. 34 Insulator assemblies 2012 Changed number of passes by spray nozzle. 35 Insulator assemblies 2012 Changed manufacturing control instructions related to

process clarification. 36 Final assemblies 2013 Changed manufacturing control instructions related to

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process change. 37 Final assemblies 2013 Revised MCI to clarify current acceptance

requirements following the actual push-out test. Product deemed suspect by the push-out tester are required to be re-measured for insert location as final decision for Pass/Fail.

38 Final assemblies 2013 Change related to adhesive & marking cure. 39 Insulator assemblies 2013 Change related to plasma treatment.

40 Plug connectors 2013 Change related to sizing of EMI spring. 41 Plug connectors 2013 Change related to cutting of EMI spring. 42 Final assemblies 2013 Change related to red & blue banding. 43 Plug connectors 2013 Change related to clicker mechanism assembly

process. 44 Composite shell assemblies 2013 ITT received 38999 Composite DLA approval in early

2013. The qualification connectors used ITT adhesive formulation SM8103-1 to bond the receptacle peripheral seal in the shell. In May 2013, ITT switched to RTV 112 as a production requested process improvement. In April 2015, ITT changed from RTV 112 to RTV 3140 or RTV 3145. RTV 112 does not comply with MIL-A-46146 and is not permitted for use in MIL-DTL-38999 products. Reference GIDEP on KJA products for additional information regarding RTV usage.

45 Final assemblies 2013 Change to manufacturing control instructions related to scratches on engaging face of shell, missing contacts, and undefined electrical test process.

46 Plug assemblies 2013 Change to manufacturing control instructions related to assembly & resizing of EMI spring on barrel.

47 Final assemblies 2013 Change to current manufacturing process to lubricate insulator stack using Isopropyl Alcohol prior to insertion into assembly tooling.

48 Socket insulators 2013 Change to current manufacturing process. Change Chemical; From: Thinner XO, To: Solvent EM 600.

49 Insulator assemblies 2013 Change to current manufacturing process. Updated to correct tooling part numbers, updated spelling errors, and updated the use of assembly aids to improve insert insertion into the connector housing.

50 Final assemblies 2013 Change to current manufacturing process. Removed lubrication process and equipment identified in the “Banding” process by error.

51 Socket front insulator 2014 Supplier request. Cannot meet tolerance on drawing. This change is being allowed because interface dimension measurements at final connector are consistently on the low side.

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52 Packaging Insulator assemblies

2013 Change to manufacturing control instructions related to Missing nut and o-ring in the connector's package and excess adhesive between hard insulators.

53 Insulator assemblies 2014 Updated to match FAIs. 54 Composite receptacle shell 2013 Improved mold fill. 55 25-29 Insulator assemblies 2014 Updated drawing to agree with tool, and accept FAIs. 56 Composite receptacle shell 2014 Changed molds to decrease void formation. Added

optional radii at the transition of the internal mating diameter to the Peripheral Seal seating surface on Size 23 and 25 WM Receptacles.

57 Pin insulator assemblies 2014 Changed drawings to match tooling and FAIs. 58 Insulator assemblies 2014 Updated to reflect current tooling results from FAIs. 59 Composite receptacles final

assemblies 2014 Parts changed to match tooling from FAI.

60 15-97 Insulator assemblies 2014 Updated to agree with tooling as recorded in FAI. 61 Final assemblies 2014 Change to manufacturing control instructions related

to process improvement. 62 15-97 Insulator assemblies 2014 Change related to tooling molds for parts that can only

hold to .004 true position. 63 All KJB rear grommets 2014 Drawings updated to agree with FAI results of tooling

and fit test results of parts. 64 Composite plug final assemblies 2015 Change to allow maximum material condition on

geometric tolerance. 65 Olive drab chromate over cadmium

plating 2016 Changed requirement for copper under plate to

electroless nickel. 66 Composite shells and barrels 2015 Clarified ramp dimensions and requirements for ease

of manufacturability. 67 Receptacle final assemblies 2015 Changed tooling to seal assembly, changed adhesive

to RTV 3140. ITT received 38999 Composite DLA approval in early 2013. The qualification connectors used ITT adhesive formulation SM8103-1 to bond the receptacle peripheral seal in the shell. In May 2013, ITT switched to RTV 112 as a production requested process improvement. In April 2015, ITT changed from RTV 112 to RTV 3140 or RTV 3145. RTV 112 does not comply with MIL-A-46146 and is not permitted for use in MIL-DTL-38999 products. Reference GIDEP on KJA products for additional information regarding RTV usage.

68 All electroless nickel hardware 2015 Changed finish note from “electroless nickel plate per FS 4971 thickness to be .0007/.0011” to “electroless nickel plate per FS-4971, thickness to be .0007/.0012.”

69 Insulator assemblies 2016 Changed leak test method. Rejection parameter adjusted. Added method for test of connectors.

70 Insulator assemblies 2016 Changed curing oven conveyor speed.

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71 Insulator assemblies 2016 Updated MCI processes from bonding all Insulator stack components together at once to a phases approach of Hard to Hard and Hard to Soft to improve overall bonding accuracy and improved Cavity to Cavity performance.

72 Insulator assemblies 2016 Change to manufacturing control instructions to add new method with cast fixtures. Updated MCI for cavity-to-cavity leak test requirements based on improved techniques and tooling for overall sealing one side of the insulator assembly prior to pressurization from the opposite side.

73 Insulator assemblies 2016 Change to manufacturing control instructions to add new recipes to bond hard-hard insulators and table #1.

74 Plug assemblies 2016 Change to method of assembly EMI spring due to customer corrective action.

75 Insulator assemblies 2016 Change to add new recipes on table #1. 76 Insulator assemblies 2016 Change to tool for alignment insulators to the tray and

change the drop water from the side to the bonding surface.

77 Plug assemblies 2017 Change to equipment to install EMI spring. 78 Insulator assemblies 2017 Change to add air dry step and alcohol replacement

frequency. 79 Insulator with plastic clips 2013 Updated material to allow up to 30% regrind in the

Torlon material. 80 Barrels and shells Sept.

2011 to Oct. 2011

Temporary change from September 2011 to October 2011 to rework all unplated parts and open up front internal bore so it is the same in both sides of the shell.

81 Barrels Sept. 2011 to

Dec. 2011

Temporary change from September 2011 to December 2011 to rework all unplated parts and open up front internal bore so it is the same in both sides of the shell.

82 Square flange shells Sept. 2011 to

Dec. 2011

Temporary change from September 2011 to December 2011 to rework all unplated parts and open up front internal bore so it is the same in both sides of the shell.

83 Jam nut shells Sept. 2011 to

Dec. 2011

Temporary change from September 2011 to December 2011 to rework all unplated parts; open up front internal bore so it is the same in both sides of the shell.

84 Plug coupling nuts Sept. 2012 to

Dec. 2012

Temporary change from September 2011 to December 2011 because the supplier created slots out of tolerance. Deviation does meet the MIL-SPEC requirements.

85 Cavity to Cavity Leak test process 2017 Change to tell operators to look at tester for 0.00 air

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flow instead of just the green light.

Page 12

APPENDIX C Summary of Field Failures and Corrective Actions

ITT observed the following field failures for the period from 2008 to the present. The field failures and associated corrective actions are summarized below. Unless otherwise noted, ITT has not been able to locate documentation confirming that it notified DLA Land and Maritime of such failures.

Item Year Report/RMA Number Description of Failure Description of Corrective

Action Lot and

Date Codes

1 2015 8709 8697

Composite connectors, coupling nut retention failure. Groove on the barrel had a rounded corner instead of a sharp corner per drawing.

The applicable report did not identify a corrective action. Based on lab reports, the Root Cause of the failure was due to a tooling issue allowing a less than optimal “locking” groove for the coupling nut mechanism. A review of the tooling was completed and modifications made to the Size 9 and 11 mold tooling to ensure proper feature definition as manufacturable and repeatable.

1326-1202, 1326-1210, 1318-637, 1318-030,

1326-1461, 1337-240, 1348-945, 1338-971, 1137-1014

2 2013 8523 Misaligned grommet to the rear insulator.

The applicable report did not identify a corrective action.

1306-1355

3 2011 8250 Customer return due to insulator movement.

EDS of adhesive requested. The applicable report indicated that the two-part adhesive was not correctly mixed by the distributor.

****-**

4 2012 N/A D38999/24: Dimensional Non-Conformance

On May 18, 2012, ITT notified DLA an out of specification condition on the following four (A, F, G & J) Jam Nut receptacle sizes per the requirements of D38999/24J, dimension “A”.

On July 11, 2012 a deviation approval was granted by DLA, including the approval to consume any existing stock at the responsibility of ITT should a customer concern or end-use issue warrant a concern for non-compliant product.

The design requirements were immediately changed to ensure compliance and to eliminate additional inventories being machined.

****-**

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Action Lot and

Date Codes

All on-hand unplated inventories of the Size A & J (Oversized) product shells were reworked to ensure compliance and to limit additional exposure should the recessed application be used. On-hand Size F & G (Undersized) product shells were deemed usable as is for existing inventory.

5 2012 N/A D38999/26: Dimensional Non-Conformance On January 20, 2012, ITT notified DLA an out of specification condition / dimensional nonconformance on the following four (A, B, D & F) straight plug sizes per therequirements of D38999/26G,dimension “K”.

On February 6, 2012 a deviation approval was granted by DLA based on the compliance redesign actions, including the approval to consume any existing stock for a period of 18 months at the responsibility of ITT should a customer concern or end-use issue warrant a concern for non-compliant product.

The deviation approval defined the following criteria:

• Current design waspermitted to be usedand existing stockmarked and sold asqualified militaryproduct for a periodof 18 months fromthe approval datelisted above.

• A new design wasrequired to besubmitted to DLAprior to August 1,2013.

Compliant product was required to be shipped after August 1, 2013.

****-**

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Action Lot and

Date Codes

6 2016 Numerous Cavity-to-cavity air leakage. See GIDEP Problem Advisory Notice PE2-P-16-01.

N/A

7 2014 60043305-10 Insulator was assembled into shell at a wrong angular position/polarization.

Manufacturing Control Instruction was revised to add a new precision press and Go/No-Go gages and training was provided to operators.

1425-244

8 2015 60045980-10 Contact was not able to be inserted due to excessive adhesive inside cavity.

Actions such as the DOE are being performed in order to prevent this reoccurrence. Scrap and replace. The DOE intended to resolve/mitigate cavity-to-cavity leakage and bonding integrity issues. Too little adhesive causes leakage, too much adhesive causes cavity blockage. The issues/problems with the bonding the hard insulators together has been disclosed in GIDEP PE2-P-16-01 initially released on January 21, 2016 and as further amended, ITT reported failures in the cavity-to-cavity leakage and bonding integrity tests. The corrective actions and risk assessment related to this failure is fully set forth in GIDEP PE2-P-16-01.

1537-1043

9 2014 60043248-10 Contact retention clip was broken, however, the clip damage could have happened by customer too.

Parts were scrapped, replacement order was put into the system and parts returned to customer.

1427-539

10 2017 60049218-10 Contact was not able to be inserted into one cavity, customer wanted only credit.

Parts were scrapped and replaced.

1633-559

11 2014 60043519-10 Excessive adhesive impacting contact insertion/seating.


1429-790

12 2014 60043567-10 Excessive adhesive on one contact clip tine, customer wanted credit.

Part was scrapped, and credit was issued to the customer.

1429-790

13 2014 60041836-10 Parts had flaked plating on the Parts were scrapped, and a 1347-926

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Action Lot and

Date Codes

receptacle. SCAR was issued against the supplier. No corrective action was taken as the parts were past 10 day warranty at the plating supplier and had been through ITT’s internal inspection and assembly process.

14 2013 60039308-10 Missing components and marking error.

Production was notified. Production was trained on non-conformance material process. Report generated based on the purchase order documentation analysis to the responsible personnel.

1314-620

15 2015 60046063-10 Workmanship, excessive adhesive in cavity.

DOE performed in order to eliminate several defects, including the epotek filtration due to gaps of the bonding. Parts scrapped and replaced.

1523-037

16 2013 60040305-10 Shipped incorrect contacts, and missed mark packaging.

Parts were reworked and replaced.

1332-2061

17 2016 60046251-10 Contact insertion issue, simulate and reship known good.

Simulation test performed on 100% of the cavities, returned good connectors and replaced the defective ones.

1523-440

18 2016 60046254-10 Contact insertion issue, simulate and reship known good.

Simulation test performed on 100% of the cavities, returned good connectors and replaced the defective ones.

1524-003

19 2014 60042633-10 Defective thread, which one is not specifically defined.

Corrective action not noted. 1141-745


Inventory segregated, parts scrapped and replaced.

1411-745


Inventory segregated, parts scrapped and replaced.

1412-620

22 2016 60046407-530

Cavity to cavity retest, 100%. 100% cavity to cavity air leakage test.

1514-009

23 2015 60044230-20 Incorrect marking, D38999/20WD19BN s/b D38999/20WD19SN.

Parts reworked and replaced. 1508-266

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Action Lot and

Date Codes

24 2013 60039710-10 60039711-10

Missing JAN in connector marking.

1) Updated CDSAs forD38999/26, D38999/24 &D38999/20.2) Train personnel on CDSAsfor D38999/26, D38999/24 &D38999/20 changes.3) Train personnel ondrawings interpretation AFarea.4) Train personnel ondrawings interpretation ABarea.

1311-419 1318-399

25 2015 60043625-10 Unable to seat contacts or very hard to seat. Do not have equipment small enough to view in holes.

Parts scrapped and replaced. 1337-693

26 2014 60041457-10 Defective plating, delamination near threads.

Salt spray test was performed to determine adhesion, results not posted.

1402-1780

27 2016 60046204-10 60046204-20

Contacts will not seat/lock into cavity/blocked.

100% contact simulation testing performed.

1533-415, 1526-1095

28 2015 60044840-10 Deformed contact pin, not connector related.

Moving forward, contacts were inspected before packaging and the packaging analyzed. If necessary, packaging will be changed to protect the contacts’ integrity.

1511-017

29 2014 60043562-10 Misaligned Grommet on connector.

1) New bonding tool will bedesigned, eliminatingopportunity to have acrooked grommet conditionon fixture and not have agood contact betweengrommet and rear insulator.2) Preventive maintenanceprogram will be implementfor Bonding fixtures(frequency "each productionorder").3) AQL .40 C=0 will bedocumented on Router byeach order to demonstratethat is preforming alignmenttest as is required. .

1412-1051

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Action Lot and

Date Codes

4) New "Bonding fixtures"will be documented on themanufacturing controlinstructions.

30 2016 60046207-10 60046207-20

Difficulty inserting contacts, all 100% simulated, 1 failed out of 10.

100% contact simulation testing performed.

1411-754

31 2013 60039008-10 Misalignment of insert in connector body.

Standardize the adhesive equipment variables set up, controlling it by a calibration sticker and monitor the adhesive variables during the working shift in a controlled form; these actions are going to be inscribed into the process manufacturing control instructions.

Implement a semi-manual insulator assembly device that will distribute a uniform insertion pressure to insulator assemblies.

Implement a cavity verification inspection and a simulator engagement verification to guarantee that the assembly cavities are according to product requirements.

1225-088

32 2014 60043527-10 Misaligned Grommet on connector.

Epotek was detected on one side of cavities, which is used on assembly area to bond insulators to the shell. Parts scrapped & replaced.

1430-795

33 2015 60043528-20 Misaligned Grommet on Parts scrapped & replaced. 1435-530

Page 18


Action Lot and

Date Codes

connector. Misalignment condition generated per bonding process, alignments tools will be implemented.

34 2014 60042328-10 Marking on cavities was illegible due to poor handling. Customer was unable to decipher cavity numbers.

Personnel was notified and re-trained on how to properly mark connectors.

1415-1005

35 2014 60043529-10 Flatness variation on insulator caused grommet to sink when contacts were inserted. Dimension measurements showed variation was .005 from one side to another.

Connectors were scrapped and replaced. Grommet vendor was contacted and a scar was placed against them.

1425-1061

36 2013 60038562-10 Incorrect insulator style was inserted into connector due to lack of verification process to detect mistakes in assembly.

Assembly process was analyzed to incorporate a pokayoke to prevent misassembly in the future. Operators were re-trained to correctly read product drawing.

1243-612

37 2013 60039639-10 Customer returned parts due to inability to insert contacts into grommet. However, once tested, contact insertion force met spec requirements of 3.6 pounds. Spec requirement is 9 points max for size 22 contacts.

Parts were returned to customer.

1315-1577

Page 19


Action Lot and

Date Codes

38 2013 60041111-10 60041111-20

Contact insertion difficulty due to misalignment of the grommet. The misalignment occurred during the bonding process and was caused by bonding base tooling misalignment.

1) Alignment simulatortooling tips were modified toimprove the cavitiesverification process.2) Retrain bonding operatorsfor proper bonding assemblyat grommet assembly duringthe lip seating verification.3) Improved bondingassembly base tools toreinforce the insulatorassembly fit.4) Updated bondingassembly manufacturingcontrol instruction to includenew assembly base fixturesto be use.5) Updated bondingassembly manufacturingcontrol instruction to includecritical to quality clausesduring grommet lip assemblyverification/replacement.6) Trained bonding processpersonnel on bondingassembly per updatedmanufacturing controlinstruction.7) During bonding basefixtures implementation,inspection for cavitiesverification and contactretention were increased to asampling plan.8) Requested grommetsupplier to include at theircomponent certificates thecuring times information.9) Product engineeringcreated a Document ChangeRequest (DCR) for grommet25-35 layout lip to improvethe insulator assemblyprocess.

1333-139, 1320-970, 1346-1026

Page 20


Action Lot and

Date Codes

39 2013 60039640-10 Contact insertion difficulty due to internal compression of old grommet style, which impacts smaller diameter PC tail contacts.

ITT tested a revised grommet design based upon DLA approval to test. Results found the design meets or exceeds the performance requirements of Mil-DTL-38999 and has eliminated the impact of the grommet sealing system on the usage of PC Tail contacts.

1215-708

40 2014 60041117-10 Contact insertion difficulty due to misalignment of the grommet. The misalignment occurred during the bonding process and was caused by bonding base tooling misalignment.

1) Alignment simulatortooling tips were modified toimprove the cavitiesverification process.2) Retrain bonding operatorsfor proper bonding assemblyat grommet assembly duringthe lip seating verification.3) Improved bondingassembly base tools toreinforce the insulatorassembly fit.4) Updated bondingassembly manufacturingcontrol instruction to includenew assembly base fixturesto be use.5) Updated bondingassembly manufacturingcontrol instruction to includecritical to quality clausesduring grommet lip assemblyverification/ replacement.6) Trained bonding processpersonnel on bondingassembly per updatedmanufacturing controlinstruction.7) During bonding basefixtures implementation,inspection for cavitiesverification and contactretention were increased to asampling plan.8) Requested grommet

1346-1026

Page 21


Action Lot and

Date Codes

supplier to include on their component certificates the curing times information. 9) Product engineeringcreated a Document ChangeRequest (DCR) for grommet25-35 layout lip to improvethe insulator assemblyprocess.

41 2014 60043434-10 Wrong angular position of grommet, which is occurring during the insulator assembly process. The assembly arbor press used was worn out causing misalignment conditions between insulators to the shell. Condition is caused by lack of preventive maintenance program for arbor press.

1) New precision press wasimplemented on assemblyprocess to avoidmisalignment conditions.2) Optical comparator is nowused to release product.3) New precision press wasdocumented on themanufacturing controlinstructions.4) Optical comparator torelease product will bedocumented on the qualitycontrol instructions.5) Preventive maintenanceprogram was created forassembly press to preventburn out condition.6) Trained personnel on themanufacturing controlinstructions.7) Trained personnel on thequality control instructions.8) FMEA 002 was updated todocument failure mode andactions implemented.

1417-843

42 2015 60045435-10 Jagged edges on cavity holes due to flash rework that occurs at external insulator manufacturer.

Parts were reworked and replaced. Large flash on parts from Supplier that Cryo-deflashing did not remove. ITT had personnel doing manual deflashing which in cases went too deep causing the reported condition. The corrective action states that the core pins design was

1531-349

Page 22


Action Lot and

Date Codes

changed by supplier. Cryo-deflash media changed.

43 2014 60043501-10 60043502-10

Incorrect part marking due to misconfigured software program used to run laser stamping machine.

1) Validated all the laserstamping programs for thereported layout and theother layouts of the samefamily group.2) Certified the stamping ofthe parts on each productionorder by the QAE.3) Final inspection will beperformed at the AQL at 1.0.4) Locked the laser computersoftware with a password toprevent the addition of anyof the loaded programs.

1442-1088, 1419-597

44 2016 60046688-10 Incorrect marking on packaging. Marking on package shows, D38999/2AFA35AN, should be D38999/24FA35AN. Marking on the part itself is correct.

Package markings were corrected and product was shipped back to the customer.

1533-1033

45 2015 60044696-10 Difficult to mate connector due to burrs on receptacle threads.

Parts were scrapped and replaced, and a SCAR was placed on shell vendor for quality issues.

1503-1163

46 2017 60049307-10 Wrong configuration was provided to the customer. Insulator should have been a socket contact configuration, and the customer was sent a pin. Root cause was likely due to mix up during packaging or inspection process.

Part was scrapped and replaced.

1336-1597

47 2015 60045770-10 The front side of insulator seal was misaligned. No root cause noted.

Part was reworked and replaced.

1525-1153

48 2015 60045116-10 Contact did not align correctly into position # two of insulator. Condition was caused by clip tines showed lower wall thickness respective to the rest of the tine walls.

A SCAR was issued to the supplier and connector was reworked and then returned to the customer.

1523

49 2017 60049026-10 Missing part marking on connector.

Part was reworked and returned to customer. Changed the inspection plan

1421-1026

Page 23


Action Lot and

Date Codes

for the visual verification from AQL 1.0 to 100% for missing marking condition in the connector.

50 2014 60041456-10 Connector was reported to have fallen apart during testing. No root cause was noted.

Process was stopped, fixtures were validated and reworked to replace springs. Preventative maintenance program was restored, and separation test was implemented for all layouts.

1348-148

51 2014 60041639-10 Connector was reported to have fallen apart during testing. This was caused by excess epoxy that was found on the cavity and was not removed due to omission of cleaning operation.

Personnel were notified and re-trained on how to properly clean and follow procedure. Part was scrapped and replaced.

1406-661

52 2016 60048151-10 Part marking on connector did not coincide with marking on packaging. Root cause was noted as an order entry error.

Marking was corrected and parts were returned to customer.

1525-924

53 2014 60042176-10 Incorrect finish was provided to customer. Order was for electroless nickel finish, customer received olive drab cadmium parts. Confusion was noted to be caused by lack of control over component placement in warehouse.

1) Provided specific locationsfor electroless nickel andolive drab shells.2) Created a quality form todifferentiate Olive Drab VsElectroless Nickel platingrequirements.3) Trained warehouse andprocess personnel on platedcomponent requirements byits part number orcomponent description.4) Improved packagingcontrol instruction, includingthe critical to qualityinformation to differentiateolive drab vs electrolessnickel plating requirements.5) Updated NGMX-FMEA-002for mixed plating finishedcomponents condition.

1405-878

54 2017 60048692-10 Incorrect insert was assembled into connector due incorrect identification during assembly

Connectors were reworked to load the appropriate insert into connector housing.

1503-1160

Page 24


Action Lot and

Date Codes

process. 55 2015 60045466-10 Contact insertion not possible

into cavities 4 and 10 due to excess adhesive found in those cavities.

Connectors were reworked and replaced.

1514-305

56 2015 60045586-10 Ground Pin A does not align with major keyway due to incorrect insert positioning.

Parts were reworked to represent correct insert alignment and returned to customer.

1416-136

57 2013 60041046-10 Jam nut was not assembled onto connector, connector was shipped without jam nut.

Process flow was analyzed to prevent future occurrences.

1332-2160

58 2014 60041180-10 60041051-10

Jam nut was not assembled onto connector, connector was shipped without jam nut.

1) Reinforced order flow atpackaging station.2) Implemented inspectionfor all manually kittedcomponents.3) Included manufacturingcontrol instruction documentat packaging to verifycomponents are included perproduction order part list.4) Include manufacturingcontrol instruction documentat packaging to includeprocess controls for manualand semiautomatic packaginginspection.5) Train process operators atpackaging manufacturingcontrol instructionimprovements.6) Reinforce qualityinspection criteria atpackaging process.7) Update process FailureMode and Effect Analysis formissing componentscondition.

1332-2160 1336-993

59 2013 60040310-10 Incorrect finish was provided to customer. Order was for electroless nickel finish, customer received olive drab cadmium parts. Confusion was

1) Provided specific locationsfor electroless nickel andolive drab shells.2) Created a quality form todifferentiate olive drab

1334-1582

Page 25


Action Lot and

Date Codes

noted to be caused by lack of control over component placement in warehouse.

versus electroless nickel plating requirements. 3) Trained warehouse andprocess personnel on platedcomponent requirements byits part number orcomponent description.4) Improved packagingcontrol instruction, includingthe critical to qualityinformation to differentiateolive drab versus electrolessnickel plating requirements.5) Updated NGMX-FMEA-002for mixed plating finishedcomponents condition.

60 2014 60042362-10 Insulator damage: 15 tines were damaged due to issues during molding process at the vendor.

Bonding process was altered to accommodate defect.

1334-1582

61 2013 60039898-10 Customer requested a socket connector, but the order was placed for a pin due to an error during order entry.

Created a new order and replaced connectors.

1311-522

62 2013 60039808-10 Customer requested a socket connector, but the order was placed for a pin due to an error during customer spec entry.

Customer spec was corrected, order was re-booked.

1311-522

63 2013 60039861-10 60040675-10

Customer requested a socket connector, but the customer received a pin due to an error during final assembly.

Operators were re-trained to understand and properly follow correct assembly procedures.

1311-522, 1341-016

64 2014 60041694-10 Customer received the wrong connector due to an error during customer spec entry.

Customer spec was corrected, order was re-booked.

1405-1662

65 2014 60042036-10 Contact retention problems on cavity 7 due to excess adhesive.

1) Preventive maintenanceimproved to cover 100%cleaning conveyor bandprocess.2) Contact simulation testAQL 1.0 changed to AQL 0.4.

1348-1223

66 2016 60046211-10 60046266-10

Contact insertion difficulty. Performed contact simulation testing on all returned connectors, replaced defective product and returned product that

1523-876 1526-651

Page 26


Action Lot and

Date Codes

passed test.

67 2012 60038426-10 Incorrect part marking, parts were marked at value added distributor.

No corrective action was provided.

1239

68 2016 60048152-10 Packaging was marked correctly, the connector provided was incorrect.

Correct product was sent back to the customer.

1331-1091

69 2016 60048410-10 Incorrect part number was received due to order entry error.

Correct product was sent back to the customer.

1331-1091

70 2014 60042561-10 Wrong angular position of insulator, which occurred during insulator assembly process. The assembly arbor press used was worn out, which caused misalignment conditions between insulators to the shell.

1) New precision press wasimplemented on assemblyprocess to avoidmisalignment conditions.2) Gage go/no goimplemented to releaseproduct and documented onthe quality controlinstructions.3) New precision pressdocumented on themanufacturing controlinstructions.4) Preventive maintenanceprogram created forassembly press to preventburn out condition.5) Trained personnel on themanufacturing controlinstructions.6) Trained personnel on thequality control instructions.7) FMEA 002 will be updatedto document failure modeand actions implemented.

1411-076

71 2016 60047226-10 Misaligned keyway due to wrong positioning of insulator before the insertion. Proper tooling was not used.

No corrective action undertaken because the issue was an isolated incident due operator error.

1542-807

72 2012 60038451-10 Damaged threads likely caused either by a misaligned thread pattern or an incorrect shell

SCAR was issued to shell supplier, parts were replaced and returned to customer.

1217-427

Page 27


Action Lot and

Date Codes

positioning with an excessive force application causing a thread deformation.

73 2013 60040836-10 Customer received the wrong connector, caused by failure to validate drawing.

1) Batch validation program:Delivery stock area willconfirm PN and Batchaccording with orderrequirements.2) Trained warehousepersonnel on batchvalidation.

1335-1584

74 2015 60044361-10 60044363-10

PC tail contacts were not in the correct position.

No corrective action was provided.

1446-618 1448-1088

75 2014 60041542-10 Compression issues and ineffective sealing system on old grommet design.

Design was replaced by new, DLA-approved design.

1334-1053

76 2016 60046252-10 60046252-20 60046258-10 60046209-10 60046210-10 60046261-10

Connectors do not accept all contacts.

The returned material is not considered as defective, only as suspect of certain defect. The connectors will be tested under the contact insertion simulation and the good connectors will be returned to the customer and if some connector is defective it will be replaced.

Perform the simulation test on 100% of the cavities, return the good ones and replace the defective ones.

1526-1003 1529-1090 1529-1083 1526-992 1526-643

1531-1500

77 2014 60043230-10 60043230-20 60043231-10 60043231-20 60043231-30 60046260-10

Pin location are in wrong position - the parts can't be assembled to the PCB.

Parts scrapped & credited. 1) New precision press wasimplemented on assemblyprocess to avoidmisalignment conditions.2) Clocking is validated byoptical comparator to releaseproduct.3) Preventive maintenanceprogram will create forassembly press to preventburn out condition.

1421-356 1422-954

1406-1040 1403-585 1523-450

78 2015 60044358-10 60044331-10

Parts received with wrong distance between pins in outer

Parts scrapped & credited. 1431-1518 1434-903

Page 28


Action Lot and

Date Codes

diameter. 79 2013 60039647-10 Grommet defective. Cannot

install contacts into connector Parts replaced. 1311-069

80 2015 60044258-10 Contacts will not lock in cavities. Parts were scrapped and replaced.

1445-501

81 2015 60044347-10 60044538-10

Contacts will not engage in numerous cavities.

Insulators defective from supplier, caused by molding process. SCAR 3528 was open to the supplier. • Will implement on cleaning

process a magnificationlight to improve thevisibility of surface.

• Leak test will be performedincreasing the AQL to 1.0C=0 be focusing on theexternal cavities.

1451-639 1451-639

82 2016 60046244-10 60046244-20


Parts seem to have adhesive in the cavities. Parts replaced. Simulate the contact insertion on the replaced connector over 100% of the cavities.

1529-142 1525-611

83 2015 60044333-10 Contact will not lock in cavities. Insulators defective from supplier, caused by molding process. In order to avoid the recurrence of the defective insulators, a SCAR was opened for the supplier to require that parts received must meet the requirements of ITT documentation for flat surfaces and burrs. In addition, a magnification light was added to the cleaning process so that any small burrs could be more easily detected prior to the bonding process.

1449-921

84 2016 60046621-10 Cavity 1 contact unable to install, excessive adhesive.

Parts were scrapped and replaced

1546-972

85 2014 60042473-10 60042473-20 60043551-10

Insert installed out of angular position.

Reported condition was caused during the insulator assembly process, The

1409-1808, 1409-1809, 1421-1489

Page 29


Action Lot and

Date Codes

assembly arbor press used was burned out causing misalignment conditions between insulators to the shell.

Root cause: Lack of preventive maintenance program for arbor press.

Escapement: This allows for personnel error during insulators assembly having only a visual inspection as a mean of detection.

Root cause: Lack of preventive maintenance program for arbor press.

86 2015 60043806-10 Insert bonded in place incorrectly. The interfacial seal separated from the insulator.

Implemented alignment fixtures for PIN insulators to improve the bonding process by guaranteeing the alignment condition between the towers seal with the insulator cavities.

1409-1804

87 2014 60043721-10 Contact insertion impacted by adhesive migration.

Will implement on cleaning process a magnification light to improve the visibility of surface. Leak test will be performed increasing the AQL to 1.0 C=0 be focusing on the external cavities. Leak test will be updated to reflect the AQL 1.0 C=0.

1414-305

88 2015 60045826-10 Cavity blockage C and D, excessive adhesive.


1441-1005

89 2015 60045986-10 Potential damage to Interfacial Seal “cone” on one cavity.


1430-412

90 2015 60043690-10 Torn interfacial seal "cone". SCAR was issued to the supplier, parts were scrapped and replaced.

1424-912

91 2015 60044353-10 #34 difficulty installing/retaining contact.

Part was passed to SQE in order to investigate with the supplier for possible molding

1443-790

Page 30


Action Lot and

Date Codes

defect.

Part was scrapped and replaced".

92 2015 60044299-10 EMI Clip installed incorrectly, allowing potential damage to functionality.

Actual assembly process is performed manually allowing misalignment condition between the lock spring and master key. In order to avoid this condition the process will be improved with a poka-yoke system performing a semiautomatic process.

Visual inspection will be reinforced with a magnification lamp after sizing machine process and will be requested 100%.

1443-1186

93 2015 60044106-10 Dent in connector body. SCAR was issued to the supplier. Parts were scrapped and replaced.

1443-1186

94 2014 60042989-10 Cavity 7 cavity tine damage/broken.

Evaluation noted to be performed in order to determine if damage was incurred by supplier. Results of evaluation not noted.

1414-703

95 2015 60045951-10 Cavity blockage due to adhesive. Actions are being performed to reduce this incident. Scrap and replace the part for the customer.

1441-346

96 2015 60044997-10 Insert installed 180 degrees out of position.

Part scrapped without CAR actions defined.

1522-1852

97 2015 60045816-10 60045817-10 60045818-10 60045819-10

Coupling nut recall. Parts recalled by ITT. 1338-971, 1326-1202, 1348-945

98 2017 60048955-10 Plating delamination at EMI spring due to excessive force applied.

Part scrapped without CAR actions defined as excessive force was inadvertently applied to install EMI spring.

1645-1483

99 2015 60045976-10 Damaged barrel, prior to plating (dented).


1536-1134

Page 31


Action Lot and

Date Codes

100 2014 60043202-10 60043202-20

Rotated insert and misalignment of grommet to insulator (separate connectors).

1) New bonding tool will bedesigned for layout 35,eliminating opportunity tohave a crooked grommetcondition on fixture.2) Preventive maintenanceprogram was implementedfor Bonding fixtures(frequency "each productionorder").

1418-1386, 1416-324

101 2015 60045471-10 Cracked barrel, unable to determine cause of damage.

Part scrapped without CAR actions defined as unable to determine who caused damage.

1533-1037

102 2015 60045138-10 Quantity: 2 defect; connector falls apart when attempting to insert crimped contacts.

The incoming folder was alerted with the orange sheet in order to verify as critical dimension and condition the groove where the EMI spring is installed.

Push-out test is being perform with an AQL = 1.0 with C = 0 as required by Mil-DTL-38999. This push-out test is being performed throughout all the sizes and production orders.

The interphase is measured to a 100% of the connectors in order to detect any displacement of the component in the assembly after the push-out test. A drop gauge is used for this purpose, so any displacement will be detected under this process.

1516-219

103 2014 60042490-10 Misaligned grommet to interfacial seal.


1342-532

104 2015 60045982-10 Damage to insulator, no definition of root cause (ITT or customer).


1534-670

Page 32


Action Lot and

Date Codes

105 2015 60044104-10 Plating delamination, no definition of root cause (ITT or customer).

One piece returned and scrapped without a CAR created. Unable to determine if wear was ITT or customer caused. Part replaced.

1423-794

106 2015 60044512-10 Cavity C blocked by unidentified source.

One piece returned and scrapped without a CAR created. Cavity determined to be blocked by FOD.

1445-512

107 2015 60044592-10 Connector returned disassembled. Insert retention tines exhibited "grease" present.

Connector returned disassembled and RC is not fully able to be determined.

1448-602

108 2015 60044366-10 Plating delamination, no definition of RC (ITT or customer).

One piece returned and scrapped without a CAR created. Unable to determine if wear was ITT or Customer caused. Part replaced.

1448-602

109 2015 60044355-10 Key damage cosmetic mark, no definition of RC (ITT or customer).

Rejection was defined as a blemish and no CAR actions identified. Part replaced as courtesy.

1423-1103

110 2015 60044718-10 60044719-10 60044720-10 60044721-10 60044722-10 60042629-10 60044105-10 60042628-10

Plating delamination at accessory teeth, no definition of RC (ITT or customer).

No corrective action was completed as it was determined by ITT and the customer that their application of the backshell caused the damage, either due to non-compliance or over torqueing.

1507-228 1421-164

1508-1140 1508-1140 1448-602

1415-1007 1432-778 1418-751

111 2015 60044364-10 60044591-10

Connector returned disassembled. Insert retention tines exhibited "grease" present.

Connector returned disassembled and RC is not fully able to be determined.

1444-443

112 2014 60043037-10 Misaligned insert in connector body. Arbor press used was worn out.

Arbor press was removed from process and replaced by a NEW precision press not allowing misalignment condition, visual inspection was replaced by gage GO-NO GO in order to perform an AQL 1.0 at level II to release connectors, preventive maintenance program will create for assembly press to prevent burn out condition for all family product.

1421-1115

Page 33


Action Lot and

Date Codes

113 2014 60041343-10 Misaligned insert in connector body

Engineering to review process and adjust as required.

1340-121

114 2014 60043300-10 Insert not seated correctly into shell (slanted).

1) New precision press wasimplemented on assemblyprocess to avoidmisalignment conditions.2) Gage go/no go will beimplemented to releaseproduct.

1348-1206

115 2012 60037900-10 Excessive adhesive at bonding surface impacting contact insertion/seating.

Created a rework order to replace insulator sub-assemblies.

1223-972, 1224-8

116 2013 60038903-10 Unable to seat contacts or very hard to seat.

Containment actions: 1) Inventory (5602pcs) forinsulator 143-2949-110 wasverified at AQL .65 80pcs zeropcs defective.2) Defective parts are oninvestigation by QE and MEto present results. Replacedparts under new sales order.

1226-677

117 2012 60038330-10 Damaged pin interfacial seal (towers).

Seal damage caused by supplier due to inadequate inspection. Scrapped and replaced.

1230-923

118 2013 60038986-10 Pin does not lock in. PN 144-2953-200 was detected deformation (burrs) inside of cavities, provoking not lock in pin.

1227-800

119 2017 60048746-10 Connector cannot be pinned. Removed the defective insulator and assembly new insulator.

1526-1214

120 2013 60040519-20 3 pieces #2 top and bottom numbers do not align, #1 & #8 pin don't lock.

Valid RPA. Replaced under new sales order. Scrapped components cannot be reworked. Process were alerted, insulator was positioned on wrong position on fixture.

1323-1918

121 2013 60040519-10 1 piece top and bottom numbers do not align.

Valid RPA. Replaced under new sales order. Scrapped components cannot be reworked. Process were

1323-1917

Page 34


Action Lot and

Date Codes

alerted, insulator was positioned on wrong position on fixture.

122 2013 60039846-10 60039846-20

Wrong key way location. Scrap components cannot be reworked. Process was alerted, insulator was positioned on wrong position on fixture, operator error. To prevent recurrence lazer will be implemented in order to stop machine process when insulator positioned on wrong position.

1312-1301, 1312-790

123 2012 60038274-10 The connector would not lock with mating connector.

Connector was received and analyzed, insulator cavities arrangement was offset from the main keyway out of requirement. RPA must be dispositioned as scrap and a replacement order must be created.

1236-599

124 2013 60040518-10 1 piece pin 31 will not lock. Defect was generated by broken tines of rear on position 31. Investigated to determine if issue was a process or supplier defect.

1323-1920

125 2013 60040500-10 D38999/26WE35SN. Numbers are backwards.

Valid RPA. Replaced under new sales order. Scrapped components cannot be reworked. Process were alerted, insulator was positioned on wrong position on fixture.

1323-1921

126 2016 60046264-10 60046263-10 60046212-10


Perform the simulation test on 100% of the cavities, return the good ones and replace the defective ones.

1524-955 1526-077 1526-634

127 2014 60041355-10 60041355-20 60041355-30

Issue RMA for return & repair/replace.

Date for 3 pieces code 1237, on 2013 process already changed. Implemented actions to prevent excess adhesive.

1237, 1240,

1210-203

Page 35


Action Lot and

Date Codes

128 2014 60041355-40 Issue RMA for return & repair/replace.

Date for 7 pieces code 1216, on 2013 Process already changed and implemented actions to prevent excess adhesive.

1216-784

129 2015 60046101-10 32 pcs. Rejected due to white grommets and date code prior to 1534; 1 pc. Rejected due to FOD on hard black mating surface and date code prior to 1534.

Make the contact insertion simulation on 100% of the returned connectors. Make inspection 100%.

Clean the reported connector with brown FOD.

Rework.

1531-169

130 2016 60046253-10 Connectors do not accept all contacts.

Rework: Test all the connectors on the contact insertion with real contacts and not with simulator. Start testing the external cavities first. Scrap the connectors with this failure and replace. Return to the customer the good connectors.

1526-005

131 2014 60042704-10 60042407-20 60042407-30 60042407-40 60042407-70 60042406-10

Wrong marking code was applied, thus, ITT Cannon description was marked instead of Military part number.

Action from order entry by Customer service department: A training session was held on Friday, June 6th, 2014 for the CSR’s and Order Entry in order to explain to customer service team what happens when they are creating new orders using a cross-reference. IT department will be create a program to allow the customer part number to populate onto the new sales order.

Assembly Area: Training on marking codes will be reinforcing to assure personnel follow marking procedure that is already established.

1416-1000 1415-308 1415-946 1415-948 1416-320

Page 36

Documents

GOVERNMENT - INDUSTRY DATA EXCHANGE PROGRAM ALERT15-5, 15-97, 17-8, 19-11 & 25-29. 2 Grommet (Phase 2) 351-2954-000 351-2958-000 & -110; 351-2959-000. 351-2965-000. 351-2976-000. ITT