Amend 0004 - SIR Section C Red Line.docx

FEDERAL AVIATION ADMINISTRATION (FAA)

CLUTTER MAP MEMORY (CMM)

CIRCUIT CARD ASSEMBLY (CCA)

July 18September 20, 2018

1.0 Introduction

1.1 Background

The legacy Clutter Map Memory (CMM) Circuit Card Assembly (CCA) is a custom designed circuit card assembly built to FAA specifications. The CMM CCA is an integral component of the Airport Surveillance Radar – Model 9 (ASR-9) system. The program management office (PMO) has determined that, to maintain and sustain the operational capability of the system, the FAA will need to procure additional CMM units. Current spare levels in stock are insufficient to sustain operational readiness. The required quantity for this procurement will help to sustain operational readiness beyond 2021. However, at that time, available spare sources will be depleted as a result of a CMM CCA that was built several decades ago, using parts, designs and technology that are obsolete, are no longer available in the marketplace, or have reached their end-of-life cycle. The design and replacement of failing parts is required to support the continuing operation of the system.

The CMM board is 1 of 10 boards used in the target and two-level weather detector function in the Radar Receiver/Processor Channel A/B (Unit 2/5), reference designation A4A110. The CMM Board A4A110 and the Clutter Map Control Board A4A112 are used to provide a scan average of the Zero Velocity Filters (ZVF) output (clutter) for the entire scan area, and a scan average of the Non Zero Velocity Filters (NZVF) outputs (residue) for the first 13 range cells. The CMM board is a storage device for the clutter data of each range/azimuth cell, and transmits data to and from clutter map control A4A112 via the output register and stimulus bus. The input data is stored in 55 128K-bit dynamic RAMs. The memory is divided into five identical banks each with 11 dynamic 64K x 2 RAMs. The output is used to recover valid zero velocity targets and provides scan–to scan storage of ZVF data.

1.2 Purpose

This Statement of Work (SOW) delineates the Contractor's work required to bring the CMM CCA, a component of the ASR-9 which forms a part of the FAA's National Airspace System, to a producible configuration.

1.3 Scope

This SOW defines the requirement to develop a CMM CCA design to a producible configuration. The anticipated acquisition is for the CMM board (CCA) designation number A4A110 only.

The Contractor must design a Form-Fit-Function (FFF) equivalent CMM CCA based on information included herein and in Section J. These items must be manufactured, assembled, and tested to meet the requirements specified in the documentation and attachments provided as part of the contract.

The Contractor must provide all required labor, facilities, tools, equipment, fixtures, parts, supplies, materials, appropriate technical data/expertise, transportation, preservation, packaging, packing and marking required to furnish the items specified in Part I – Section B in accordance with (IAW) the terms, conditions, and provisions set forth herein.

Each FFF term defines a specific aspect of the requirement for a CMM CCA that conforms to Government requirements, as follows:

1. Form refers to such characteristics as external dimensions – weight, size, and visual appearance of a part or assembly. This is the element of “form” that is most affected by design choices, including enclosure, chassis, and control panel, that become the outward "face" of the product.

2. Fit refers to the ability of the part or feature to connect or join to another feature or part within an assembly. The “fit” allows the part to meet the required assembly tolerances.

3. Function is a criterion that is met when the part meets performance and operational requirements as defined by this SIR. In an electronics product, for example, function can depend on the solid-state components used, software or firmware, and quite often on the features of the electronics enclosure selected.

International Traffic in Arms Regulation (ITAR) compliance is not required for CMM.

2.0 Applicable Documents

The following specifications, handbooks, orders, standards, and drawings form a part of this SOW and are applicable to the extent specified herein. The latest version of these documents as of the contract date must apply. In the event of conflict between this SOW and any of the applicable documents cited below, the provisions of this SOW must apply. They are listed in the table below, cross-referenced to the applicable FFF requirement:

1. Clutter Memory CCA (1D21061G01_2A4A110) Control Signals. pdf

X

4. TI 6310.38 – FIGURE 11-163 64Kx2-Bit DRAM Data Sheet

X

5. FAA-G-2100H – Electronic Equipment, General Requirements, Applicable sections:

· 3.2.2.1 (to include subsections) Printed Circuit Boards

· 3.3.1.4.7 Conformal Coating of Printed Circuit Boards

· 3.3.1.4.8 Electromagnetic Shielding

Offerors are hereby advised that the attachments identified in the table above are intended for informational purposes only as an aid in the development and delivery of requirement documents as specified below. They are not to be construed as CMM CCA design or manufacturing specifications.

Prior to commencement of prototype development and production, the Contractor will conduct a Critical Design Review (CDR) to allow the FAA’s review of the Contractor’s design of the CMM CCA. The review must be conducted no later than 90 days after contract award.

The Contractor must support a CDR to take place at AJW-146 / ASR-9 RADAR Building 270, William J. Hughes Technical Center (WJHTC), Atlantic City, New Jersey 08405. The Contractor will ensure that personnel critical to supporting the CDR are in attendance or are available by teleconference.

At the CDR, the Contractor must:

1. Describe the products, processes, methodologies, milestones, and measurements to be used in conducting development activities;

2. Present data flow and control flow diagrams describing design solutions;

3. Present design decisions defined and recorded for the CMM CCA; and

4. Document minutes, action items, and provide presentation materials.

As part of the CDR, the Contractor must present the following documents to the Government:

1. Detailed design approach, including interfaces;

2. Functional flow and schematic diagrams;

3. Physical description including lists of materials, parts, manufacturing flow processes, and board layout;

4. Producibility analysis;

5. Identification of design-driving/cost driving developmental elements;

6. Component level reliability and maintainability predictions;

7. Design concerns such as environmental control, electromagnetic compatibility/interoperability and derived design requirements; and

All CDR deliverables under CLIN 0001 may be submitted using a contractor’s format. CDR deliverables must be provided to the Government at least ten (10) days prior to the CDR. The Government requires schematic and PCB layouts to be furnished in Altium.

3.2 CDR Acceptance Criteria

To successfully complete CDR, the Contractor must present evidence of meeting the following requirements:

1. Present a detailed design that shows a FFF equivalent CMM CCA in accordance with the seven documents listed in Section 3.1 that are presented at CDR (e.g., detailed functional analysis, functional flow and schematic diagrams, etc.);;

2. Present sufficient data, analysis and detail to show that requirements of the SOW will be met; and

3. Provide resolution, or an acceptable plan for resolution, of all action items.

The Contractor is required to successfully complete CDR Acceptance Criteria no later than 30 days after completion of CDR.

Non-Recurring Engineering (NRE) as well as all costs associated with the activities identified above must be accounted for as part of this CLIN.

4.0 Prototype Units (CLIN 0002) (FFP)

The Contractor must design, build, test and deliver two (2) Prototype CMM CCA units. The purpose of the prototype units is to successfully demonstrate the Contractor’s proof of concept design. Prototype production must not commence prior to FAA approval of the design. (CLIN 0001).

Deliverables under this CLIN must include:

1. Prototype units (hardware and software);

2. Development Test Plan and Procedures;

3. Development Test Reports;

4. Bill of Materials (BOM);

5. List of test tools (hardware and software) used to support CMM CCA development and testing;

6. Manufacturing specifications;

7. Schematics, Printed Circuit Board (PCB) layout design (e.g.,in Altium),, JDEC (if applicable) and output files (e.g., Gerber; and

8. Programmable logic source code (if applicable).

Contractor format is acceptable.

For all data deliverables listed above the Contractor must provide the following:

1. BOM in MS excel format.

2. Schematics and PCB design file in Altium Designer format.

3. All mechanical drawings in Adobe pdf and AutoCAD drawing format.

4. All other documents in Adobe pdf and MS word format.

The Contractor must provide a Development Test Plan and Procedures to the FAA within 30 days of FAA approval of the design. (CLIN 0001). The objective of Development Test Plan and Procedures is for the Contractor to prove that the CMM CCA meets all specifications and FFF requirements. The Government will review the Development Test Plan and Procedures within 30 days after receipt.

All other deliverables under CLIN 0002 are due to the FAA within 120 days of FAA approval of the design. (CLIN 0001) The Development Test Plan and Procedures must:

1. Include a separate test plan and procedures for each test to be conducted by the Contractor;

2. Cover all tests required for the conduct of all tests identified in the Development Test Plan;

3. Be separately identified;

4. Meet those performance parameters and operating characteristics of the design criteria;

5. Include detailed planning information for test conduct. Information must be to a level necessary to show adequacy of the test methods and test limits. Specific methods for performance measurement must be included:

a) Form/Fit: mechanical compliance of all card dimensions, extractors, and Input/ Output (I/O) connector placement;

b) Function: memory read/write for all addresses;

c) Environmental: functional test in environmental chamber based on the following environmental conditions:

· Temperature: 32º Fahrenheit to 122º Fahrenheit (0 to +50 º Celsius)-40C to 85C

· Relative Humidity: 5% to 90%

· Elevation: 0 to 10,000 feet above sea level ; and

d) Timing Analysis: Memory read/write setup and hold verification.

Note that the format of the Development Test Plan and Procedures must be specified by the Contractor. All test equipment (hardware and software) must be certified and validated prior to test. The Government reserves the right to witness any and all Development Testing activity conducted by the contractor at the contractor’s facility or FAA facility. While the contractor can perform the majority of development testing at contractor’s facility, the contractor may also elect to conduct any relevant testing at the FAA WJHTC, Building 270, Atlantic City, New Jersey utilizing Government’s ASR-9 system.

The Development Test Report must:

1. Document Development Test results. The reports are used to identify and evaluate discrepancies between expected and actual test results.

2. Address each test identified in the Development Test Plan and Procedures.

3. Address each test and associated test result separately and be identifiable.

4. Be in a contractor-specified format.

The Government will review the Development Test Report within 30 days after receipt.

4.1 Prototype Integration Testing

The FAA will perform functional testing on the delivered CMM CCAs to confirm functionality of the units. Any issues with the functional testing will be submitted in writing to the Contractor, who must provide resolution, subject to Government approval, of all identified issues no later than 30 days from receipt of Government comments. Prototype Integration Testing will be performed by the FAA at the WJHTC, Building 270, Atlantic City, New Jersey. The FAA will work jointly with the Contractor to integrate the CMM CCAs into the ASR-9 Radar System. The Contractor may be onsite at the WJHTC and assist in any special instructions or handling of the prototypes as well as witness the test in process, take notes, and if necessary, assist in troubleshooting, take measurements, or change firmware/software if any concerns identified.

4.2 Prototype Unit Acceptance Criteria

To successfully complete Prototype Unit Acceptance Criteria, the Contractor must present evidence of meeting the following requirements:

1. Government approval of Prototype Unit deliverables; and

2. Resolution, or an acceptable plan for resolution, of all action items and comments

Non-Recurring Engineering (NRE) as well as all costs associated with the activities identified above must be accounted for as part of this CLIN.

5.0 Pre-Production Units (CLIN 0003) (FFP)

Upon the successful completion of functional testing of prototype units (CLIN 0002), and at the FAA’s direction, the Contractor must design, build and deliver two (2) pre-production CMM CCAs and supply them to FAA (AJW-146) for system testing. The purpose of the pre-production units is to confirm validation of the design as a manufacturing standard.

Deliverables under this CLIN must include:

1. Updated Development Test Plan and Procedures;

2. Pre-Production units (hardware and software);

3. Development Test Reports;

4. Updated BOM;

5. List of test tools (hardware and software) used to support CMM CCA development and testing;

6. Updated manufacturing specifications;

7. Updated schematics, Printed Circuit Board (PCB) layout design (e.g.,using Altium),, JDEC (if applicable) and output files (e.g., Gerber);

8. Updated programmable logic source code (if applicable); and

9. Factory Acceptance Test (FAT) Plan and Procedures.

Contractor format is acceptable.

For all data deliverables listed above the Contractor must provide the following:

1. BOM in MS excel format.

2. Schematics and PCB design file in Altium Designer format.

3. All mechanical drawings in Adobe pdf and AutoCAD drawing format.

4. All other documents in Adobe pdf and MS word format.

The Contractor must provide an updated Development Test Plan and Procedures to the FAA within 30 days of FAA approval of the prototype. (CLIN 0002). The objective of Development Test Plan and Procedures is for the Contractor to prove that the CMM CCA meets all specifications, and all FFF requirements. The Government will review the Development Test Plan and Procedures within 30 days after receipt.

All other deliverables under CLIN 0003 are due to the FAA within 120 days of FAA approval of the prototype units. (CLIN 0002)

5.1 Factory Acceptance Test Plan and Procedures

The Contractor must develop a Factory Acceptance Test (FAT) Plan and Procedures.

The FAT Plan and Procedures must be reviewed and approved by the FAA prior to its implementation on the first article units (CLIN 0004). The FAT Plan and Procedures must also address the requirements of factory testing and inspection as stated in the quality section.

For each CMM CCA, electrical continuity & isolation PCB must be performed. for the blank, unassembled PCBs.

For the final CMM CCA assembly, IPC-A-610B Class 3 compliance inspections and the FAT procedures must be performed. Installation, integrity, and labeling of the components must be physically verified as part of the FAT.

5.2 Pre-Production Integration Testing

The FAA will perform system testing on the delivered CMM CCAs to confirm functionality of the units. Any issues with the system testing must be submitted in writing to the Contractor, who will provide resolution, subject to Government approval, of all identified issues no later than 30 days from receipt of Government comments. Pre-Production Integration Testing will be performed by the FAA at the WJHTC, Building 270, Atlantic City, New Jersey. The FAA will work jointly with the Contractor to integrate the CMM CCAs into the ASR-9 Radar System. The Contractor may be onsite at the WJHTC and assist in any special instructions or handling of the prototypes as well as witness the test in process, take notes, and if necessary, assist in troubleshooting, take measurements, or change firmware/software if any problems are found.

5.3 Pre-Production Unit Acceptance Criteria

To successfully complete Pre-Production Unit Acceptance Criteria, the Contractor must present evidence of meeting the following requirements:

1. Government approval of Pre-Production Unit deliverables; and

2. Resolution, or an acceptable plan for resolution, of all action items and comments.

Non-Recurring Engineering (NRE) as well as all costs associated with the activities identified above must be accounted for as part of this CLIN.

6.0 First Article Units (CLIN 0004) FFP

Upon the successful completion of pre-production unit testing (CLIN 0003), which must confirm to the FFF of the pre-production units, the Contractor must build and deliver six (6) CMM CCAs First Article Units and supply them to FAA (AJW-146) for system testing and Government approval.

Deliverables under this CLIN must include:

1. Final Development Test Plan and Procedures;

2. First Article units (hardware and software);

3. Final Development Test Reports;

4. BOM;

5. List of test tools (hardware and software) used to support CMM CCA development and testing;

6. manufacturing specifications;

7. schematics, PCB layout design (e.g.,using Altium),, JDEC (if applicable) and output files (e.g., Gerber);

8. l programmable logic source code (if applicable); and

9. Final FAT Plan and Procedures.

Contractor format is acceptable.

For all data deliverables listed above the Contractor must provide the following:

1. BOM in MS excel format.

2. Schematics and PCB design file in Altium Designer format.

3. All mechanical drawings in Adobe pdf and AutoCAD drawing format.

4. All other documents in Adobe pdf and MS word format.

The Contractor must provide an updated Development Test Plan and Procedures to the FAA within 30 days of FAA approval of the pre-production unit. (CLIN 0003). The objective of Development Test Plan and Procedures is for the Contractor to prove that the CMM CCA meets all specifications, and all FFF requirements. The Government will review the Development Test Plan and Procedures within 30 days after receipt.

All other deliverables under CLIN 0004 are due to the FAA within 90 days of FAA approval of the pre-production units. (CLIN 0003)

6.1 First Article Test

The FAA will perform First Article testing on the delivered CMM CCAs to confirm functionality of the units.

First Article Test will include:

1. Functional Configuration Audit (FCA) and Physical Configuration Audit (PCA)

2. Operational Functional Testing

3. Burn-In or Reliability Testing

4. Execute regression and compatibility testing (i.e., one CMM or two CMMs in system) The FAA has 60 days to perform First Article Testing after receiving the First Article CMM CCAs. If First Article Testing is successful, the FAA will write a Release for Production document at which time the Contractor may begin production. There may be conditional acceptance or approval.

6.2 First Article Unit Acceptance Criteria

Once the FAA has verified that the first articles have passed a PCA as well as installation and system tests, a written approval will be issued to the Contractor by the Contracting Officer (CO) IAW AMS Clause 3.10.9-2 First Article Approval – Government Testing (July 2003) and AMS Clause 3.10.4-2 Inspection of Supplies, Fixed Price (November 1997). The Contractor must provide resolution, or an acceptable plan for resolution, of all comments no later than 30 days from receipt of Government comments. Upon Contractor delivery of the First Article units the Government will inform the Contractor of its determination no later than 30 days from receipt.

7.0 Production Units (CLIN 0005) FFP

Upon acceptance of First Article units, and upon direction by the FAA, the Contractor must commence production of the thirty (30) CMM CCA units. The Contractor must manufacture and test the required contract quantity of CMM CCAs utilizing the Government-approved First Article as the production quantity standard along with the FAA-approved specification, drawings and other defining documentation.

The Contractor must test each completed CMM IAW the approved FAT Plan prior to release for shipment to the FAA.

Deliverables include:

1. Final BOM;

2. Final manufacturing specifications;

3. Final schematics, PCB layout design (e.g., Altium Designer format), JDEC (if applicable) and output files (e.g., Gerber);

4. Final programmable logic source code (if applicable); and

5. Final FAT data sheets and report. The Contractor must include a FAT data sheet for each CMM CCA delivered. The FAT data sheet should include the serial number of each CCA, quality conformance inspection results, and the result of the FAT verification.

For all data deliverables listed above the Contractor must provide the following:

1. BOM in MS excel format.

2. Schematics and PCB design file in Altium Designer format.

3. All mechanical drawings in Adobe pdf and AutoCAD drawing format.

4. All other documents in Adobe pdf and MS word format.

Under CLIN 0005, the Government requires 10 units per month (based on a total of 30 CMM CCA units) with delivery commencing 90 days after Government acceptance of First Article units.

8.0 Material Procurement and Fabrication

1. Upon receipt of first article approval, the Contractor must procure the materials required to manufacture the remaining production contract quantity of CMM CCAs.

2. The Contractor should use caution and not deviate from the materials or manufacturers used in the first article unless such deviation has been previously approved by the CO.

3. The Contractor must include a FAT data sheet for each CMM CCA delivered. The FAT data sheet must include the serial number of each CCA, quality conformance inspection results, and the result of the FAT verification.

9.0 Test Equipment (CLIN 0006) (FFP)

The Contractor must provide any test tools developed with the test procedures and custom software and/or hardware for board level testing and troubleshooting. Custom hardware may include prototype CCAs that may contain standalone circuitry or partially integrated circuitry as well as interfaces to interface or communicate with the prototype circuitry and/or diagnostic test equipment. This would include all test tools used from development to prototype/pre-production. Offerors must propose test equipment as fully integrated. Test tools must be delivered at First Article and an updated set of deliverables provided with the production units. This would also include any updates made after First Article.

10.0 Optional Production Units (CLIN 0007) FFP

The Government reserves the right to purchase additional production units as required during the term of this contract, and may exercise this option within ten (10) days from the date of delivery of the final production unit.

11.0 Data Rights

The Contractor must provide the Government with rights to all data, drawings and specifications associated with CMM CCA as defined in AMS Clause 3.5-13 Rights in Data-General (October 2014).

12.0 Government Furnished Equipment

The Government will furnish the Contractor, as Government Furnished Property, a legacy CMM CCA to support design and development within 15 days after contract award. The legacy CMM CCA must be returned to the Government when directed by the FAA or upon Contractor delivery and Government acceptance of production units.

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