Slip Ring STATEMENT OF WORK 4-25-2019.docx

Terminal Doppler Weather Radar (TDWR) Slip Ring Assembly Acquisition Contract AJW-1442, Terminal Doppler Weather Radar Second Level Engineering Branch

STATEMENT OF WORK

For Terminal Doppler Weather Radar (TDWR) Slip Ring Assembly

TABLE OF CONTENTS

OVERVIEW

The Terminal Doppler Weather Radar Second Level Engineering Branch, AJW-1442, a division of the Federal Aviation Administration (FAA) Weather Systems Engineering Branch, requires the manufacturing of new slip ring assemblies in support of the Terminal Doppler Weather Radar (TDWR). The new slip ring assembly is to be compatible with the Brushless Antenna Drive Motor equipped TDWR while providing long, reliable service with low maintenance requirements. This Statement of Work describes the FAA’s requirements for this procurement.

Contracting Officer’s Representative (COR) The Contracting Officer’s Representative (COR) is formally designated this responsibility by the Contracting Officer to provide technical direction and Government oversight to the Contractor on matters related to this contract.

SCOPE OF WORK

The Contractor will furnish labor, plant facilities, parts, supplies, materials, fixtures, equipment, tools, test equipment, technical data/expertise, and other facilities necessary to design and manufacture the required number of TDWR slip ring assemblies in accordance with this document and specifications, drawings, and other defining documentation provided by the FAA as attachments to the Screening Information Request/Request for Offer (SIR/RFO).

QUALITY CONTROL

Auditable System The Contractor will establish and maintain an auditable system containing all elements of the ANSI/ASQ/ISO Q9001-2008 standard. Applicable International Personnel Certification (IPC) workmanship standards will be followed.

Equipment Inspection Equipment will be inspected in accordance with its conformance to Technical Specifications and Packaging Specifications as stated in the contract. The equipment will be accepted/rejected at destination by the FAA. Certificates of Conformance shall be supplied where applicable. The Contractor may find information at http://www.asq.org.

Government Inspection The Government and the Contractor agree that equipment contained in the TDWR systems are standard manufactured items. For that reason, it should not be necessary to require Government inspection and examination of all work in progress. However, if an abnormal failure rate (to be determined by a Systems Engineer) is experienced, both parties agree that an in-plant quality control review shall be provided.

CONTRACTOR TASKING/REQUIREMENTS

Throughout the life of the contract, the Contractor will provide a full range of program management support for the FAA (specifically AJW-1442). Contractor tasks and requirements include, but are not limited to, the following:

Program Management The Contractor will provide the COR and Contracting Officer with monthly reports describing status of contract deliverables. Monthly status reports will include the following minimum information [CDRL A001]:

1. Contractor developed and maintained realistic schedule for meeting the Milestone Deadlines shown in Table 8-1. Note: The most critical deadline is Milestone 5, the first delivery of the first four production slip ring assemblies following Notice to Proceed.

2. Status of project milestones and deliverables.

3. Potential impacts or delays, if present, that could affect progress of project milestones and mitigation strategies.

Slip Ring Assembly Design and First Article Production Slip Ring Assembly Design The Contractor will develop a slip ring assembly design in accordance with this document and the referenced specifications, drawings, and other defining documentation provided by the FAA. The Contractor will submit the design, in the form of general drawing package, to the FAA for review and approval prior to its use [CDRL A002]. At a minimum, the general drawing package should describe form-fit-function, connector requirements, and interconnection related dimensioned drawings; electrical properties and requirements, an assembly circuit diagram, ring layout, and maintenance/care requirements should also be contained in the drawing package. FAA review of the slip ring assembly design should be complete within 3-7 days of receipt of the design for review.

Compatibility with TDWR Brushless Motors The TDWR slip ring assembly designed for the FAA must be electrically compatible with TDWRs equipped with brushless motor equipment; these requirements are stated in the FAA Slip Ring Assembly Specification Document (Refer to Section J of the SIR/RFO).

Form and Fit Requirement The “Form” and “Fit” requirements of the slip ring assembly’s design allow for a slight increase in length and/or diameter, assuming certain conditions are met. The vendor may depart from the desired slip ring assembly length and/or diameter, shown in FAA Drawing AE-D-2337-1, only if, in doing so:

1. Initial procurement costs are reduced, Lifecycle; i.e. removal, maintenance, repair, and reinstallation, costs are reduced, Maintenance requirements decrease, and/or Mean Time Between Failure (MTBF) increases;

2. The Contractor includes all components and hardware necessary to replace TDWR infrastructure affected by the deviation from the FAA’s desired length and/or diameter of the slip ring assembly; e.g., Infrastructure components most likely affected by an increase in the slip ring assembly’s length are the slip ring assembly support arm, waveguide sections above and below the TDWR azimuth rotary joint;

3. The design does not require special or exotic parts, tools, maintenance actions, or special skills to install;

4. The design does not interfere with normal maintenance activities of other TDWR parts and equipment; e.g. removing and replacing the motor units

Regardless of dimensional changes, the Contractor must deliver a complete turnkey solution that is immediately compatible with a brushless motor equipped TDWR system. The Contractor’s proposal must include the cost of replacing pedestal infrastructure components impacted by their design. Interface with the FAA Contracting Officer’s Representative (COR) to obtain specifications and drawings for use in defining modifications to or replacements of infrastructure components/equipment affected by increased dimensions of the slip ring assembly design.

First Article After FAA approval of the slip ring assembly design, the Contractor will manufacture one (1) TDWR slip ring assembly for first article testing. Once the FAA has verified acceptable performance of the first article slip ring assembly, according to the FAA’s First Article Test Procedure, a Notice to Proceed (NTP) with production of remaining slip ring assemblies will be issued to the vendor by the Contracting Officer (CO).

Slip Ring Assembly Production Bulk Material Procurement Upon receipt of Notice to Proceed (NTP), the Contractor may procure, in bulk, the materials required to manufacture the remaining contract quantity of TDWR slip ring assemblies. If this task cannot be completed in one (1) procurement, i.e., one procurement of all the material needed from each source, the Contractor should strive to procure all material with a minimum number of orders.

The requirement for bulk (that is, upfront) procurement of materials for the entire slip ring assembly manufacturing process may be waived, in part or in whole, if it is not beneficial to the project’s production schedule, efficiency, or cost. Notify the FAA Contracting Officer (CO) if this task is to be waived.

External Fabrication Upon receipt of NTP, the Contractor may procure, in bulk, components that must be fabricated by an External Source. The Contractor will procure the fabricated components required for the remaining contract quantity of TDWR slip ring assemblies. If this task cannot be completed in one (1) procurement; i.e., one procurement from each outside source, the Contractor should strive to procure all “external source” fabricated/machined components using a minimum number of orders.

“External Source” component fabrication is to be conducted in the manner (and quantity) deemed most efficient by the Contractor. This task may be waived, in part or in whole, if it is not beneficial to the project’s production schedule, efficiency, or cost. Notify the FAA Contracting Officer (CO) if this task is to be waived.

In-House Fabrication Upon receipt of NTP, the Contractor, for “In-House” fabrication activities, may fabricate in advance, the parts and/or components required to manufacture the remaining contract quantity of TDWR slip ring assemblies. This will be referred to as “In-House component fabrication” in accompanying documents.

“In-House” fabrication is to be conducted in the manner (and quantity) deemed most efficient by the Contractor. This task may be waived, in part or in whole, if it is not beneficial to the project’s production schedule, efficiency, or cost. Notify the FAA Contracting Officer (CO) if this task is to be waived.

Storage of Materials and Fabricated Components Materials and fabricated components are to be stored at the Contractor’s facility; should offsite storage be required, permission must be obtained from the designated FAA Contracting Officer (CO).

Manufacture to Design and Requirements After receiving Notice To Proceed (NTP), the Contractor will manufacture the required contract quantity of TDWR slip ring assemblies in accordance with the Contractor’s FAA-approved design.

Rate of Delivery Slip Ring Assemblies are to be manufactured at a rate compatible with a delivery schedule of two (2) slip ring assemblies per month, minimum. If the Contractor has an optimum production rate, that will reduce production risks, time, and/or cost and this optimum rate (for production and, therefore, delivery) is above two (2) slip ring assemblies per month, the contactor may propose a more aggressive delivery schedule. Written CO permission is required for any deviation below the required two (2) units per month minimum.

Acceptance Testing Acceptance Test Procedure At a minimum, the Contractor will develop an Acceptance Test Procedure (ATP) addressing the performance parameters listed in Exhibit 2 [CDRL A003]. The ATP must be reviewed and approved by the FAA prior to its implementation on the first article slip ring assembly.

Testing The Contractor will test each completed slip ring assembly in accordance with the ATP prior to release for shipment to the FAA. A copy of the ATP results will be included in the assembly’s packaging [CDRL A004].

Data Transfer Rights in Data The Contractor will prepare and submit a quote for the cost of acquiring Government Purpose Rights in Data for the TDWR slip ring assembly; this quote is to be valid throughout the contract’s duration should the FAA decide to procure the data rights during that time frame. The level of data rights, and design information accompanying them, must provide the FAA with the ability to repair, manufacture, modify, or redesign the slip ring assembly with any vendor in accordance with Government Purpose Rights.

Once the Rights in Data, above, are granted to the FAA, the Contractor will update the drawing package provided in Section 4.2.1 of this Statement of Work, accordingly, to allow for the FAA to accomplish the actions described above.

GOVERNMENT INSPECTION AND ACCEPTANCE

Inspection and Acceptance TDWR slip ring assemblies will be inspected and accepted/rejected at destination by the FAA.

Deficient and Non-conforming Items not meeting the requirements in this SOW and all applicable standards will be classified as deficient and non-conforming. Deficiencies will be corrected by the Contractor at no additional cost to the Government. The CO will request a Return Material Authorization (RMA) number from the Contractor for each item that does not meet standards and requirements at testing prior to returning the item to the Contractor. After the required corrections, the part will be returned to the FAA with a 4650-12 Form obtained from the COR. The returned item shall be plainly marked “Reworked” and returned to the FAA, packaged and shipped in accordance with the packaging and shipping instructions.

Warranty A standard manufacturer warranty will apply to the slip ring assembly; however, the FAA requires the option of additional coverage. The goal of this warranty is to ensure the contractor’s claims for MTBF and maintenance intervals are met. The Contractor’s proposal will identify the cost of the optional extended warranties described below:

1. A seven (7) year Extended Standard Warranty providing coverage against defects in workmanship and materials. At the conclusion of the first year of coverage, the coverage of the warranty should be prorated. For example, after 4 years, the warranty would only cover 50% of warranty repair costs. The warranty is to commence after shipment.

2. A three (3) year Extended Standard Warranty providing coverage against defects in workmanship and materials. The warranty is to commence after shipment.

If the FAA does not choose to utilize one of the warranties above, a standard manufacturer’s warranty will apply.

DELIVERABLES

TDWR slip ring assemblies shall be delivered in accordance with Section 4 of this Statement of Work. In addition, the Contractor will deliver all required data defined above and listed in the Contract Data Requirements List (CDRL), Exhibit 3.

SCHEDULE

Table 8-1 represents the FAA’s desired schedule for completion of project milestones with respect to the contract award date. The deadline for Milestone 5 is the most critical to the FAA’s schedule requirements, and must be maintained. However, if beneficial to the FAA and the Contractor, an alternate schedule for Milestone completion may be proposed. Any alternate schedule must ensure completion of Milestone 5 on or before the date specified in Table 8-1.

Table 8-1: Milestones

PERIOD OF PERFORMANCE

Work under this contract is expected to take place during a two (2) year period.

PLACE OF PERFORMANCE

Work performed under this contract will be performed on the Contractor's premises and in the Contractor’s facilities.

SHIPPING REQUIREMENTS

Shipment All assets will be shipped FOB Destination.

Address for Shipment Unless otherwise directed by the Contracting Officer (CO), address all TDWR slip ring assemblies for shipment to the FAA at the following address:

FAA Aeronautical Center AJW-144, Bldg. 201 6500 S. MacArthur Blvd.

Oklahoma City, Ok 73169-6901 Packaging, Handling, Storage, and Transportation (PHS&T) The Contractor is to package the manufactured TDWR slip ring assemblies in accordance AC Form 4770-14 provided as an attachment to the SIR/RFP.

The Contractor will label the assembly’s packaging with the following information:

National Stock Number - 0000-00-012-1909 Part Number – Contractor format is acceptable Serial Number - Contractor format is acceptable Revision Level – Contractor format is acceptable Contract Number – (As found on the contract)

EXHIBIT 1: LIST OF APPLICABLE STANDARDS, GUIDANCE, DOCUMENTS, ETC.

The Contractor will perform all work detailed in this SOW in accordance with the documents reflected in the table below:

EXHIBIT 2: ACCEPTANCE TEST PROCEDURE (ATP) MINIMUM TEST SET PARAMETERS

The slip ring assembly ATP should address the following tests; refer to the FAA Slip Ring Assembly Requirements Document.Acceptance Test Standard/Requirement Static Circuit Resistance Less than/equal to 200 milliohms Ring Noise (Dynamic Circuit Resistance) Less than 30 milliohms at 50 milliamps at 5 RPM Insulation Resistance Greater than 500 MEGOHMS for circuits 1-21 Greater than 200 MEGOHMS for circuits 22-73 Dielectric Strength Test (non-destructive) Vendor recommended Starting Torque 10 ft-lbs. maximum Physical/Mechanical Requirements Verify that assembly is built in accordance with the approved design (dimensions, connectors, etc.)

EXHIBIT 3: CONTRACT DELIVERABLES

CONTRACT DATA REQUIREMENTS (CDRL). The Contractor shall provide all of the following CDRLs during the course of the contract on the schedule noted in the table below; data contained in these CDRL documents is described fully in the pages following this table.CDRL NUMBER

DESCRIPTION

Frequency Deadline of Submission to COR and CO Not separately priced (NSP) or Separately Priced (SP) A001 Monthly Status Update Report Monthly End of Month

NSP

A002 Slip Ring Assembly Design One Time/Revision as Necessary Within 60 days of contract award or 15 days prior to start of first article manufacturing. FAA review and approval is required before it is implemented.

NSP

A003 Acceptance Test Procedure (ATP) Description One Time with Review 30 days prior to application to the First Article Slip Ring Assembly to COR

NSP

A004 Acceptance Test Procedure Results ATP Results included with each slip ring assembly At time of shipping, include in packaging

NSP

CDRL A001: Monthly Status Update Report Content as described in Section 4.1 of this statement of work. Vendor format is acceptable. Submit electronically, via email, to the Contracting Officer and the Contracting Officer’s Representative (COR).

CDRL A002: Slip Ring Assembly Design Content as described in Section 4.2.1 of this statement of work. Adherence to the ASME Standard, Y14.100-2004, “Engineering Drawing Practices” and requirements of the FAA TDWR Slip Ring Assembly Form, Fit, Function Drawing, Drawing Number AE-D-2337-1 and AE-D-2337-2.

CDRL A003: Acceptance Test Procedure (ATP) Description Document Content as described in Section 4.4.1 of this statement of work. Vendor format is acceptable. Electronic submission via email to the Contracting Officer’s Representative (COR)

CDRL A004: Acceptance Test Procedure Results A copy of the ATP results will be included in the each slip ring assembly’s packaging. Vendor format is acceptable.