Statement of Work - 70Z03825QB0000061 Amendment 5.pdf

STATEMENT OF WORK (SOW)

70Z03825QB0000061

Amendment 5

1.0 SCOPE

This requirement is for a form, fit, and function replacement of MH-65 legacy Night Vision

Imaging System (NVIS) compatible incandescent light indicators for the United States Coast

Guard (USCG) Helicopter. The requirement includes procurement of new production Light

Emitting Diode (LED) indicators, and miscellaneous replacement parts. Engineering support services, design modification, and product improvement efforts may also be performed under this contract.

2.0 BACKGROUND

This upgrade includes extensive modifications of the aircraft electrical systems. New LED indicators for the instrument panels are required to replace the obsolete incandescent indicators to support electrical panel operation for the next 20 years. The aircraft is NVIS compliant, and all LED indicator assemblies must be manufactured in compliance with NVIS compatibility standards.

Newly designed and manufactured LED indicator assemblies shall fit current MH-65E panel cut outs and interface with existing wiring detailed in this SOW.

3.0 APPLICABLE DOCUMENTS AND DESIGN CRITERIA

3.1 Government Documents

The following specifications, standards, and handbooks of the latest revision at the date of the original release of this specification listed below form a part of this specification to the extent specified herein.

DEPARTMENT OF DEFENSE (DOD) STANDARDS:

MIL-STD-3009, 02 February 2001 LIGHTING, AIRCRAFT, NIGHT VISION IMAGING

SYSTEM (NVIS) COMPATIBLE

MIL-DTL-7788H, 18 October 2011 PANELS, INFORMATION, INTEGRALLY

ILLUMINATED

MIL-STD-130N w/CHANGE 1, 16 November 2012 IDENTIFICATION MARKING OF US MILITARY

PROPERTY

FEDERAL AVIATION ADMINISTRATION (FAA):

AC29-2C, Change 3 CERTIFICATION OF TRANSPORT CATEGORY

ROTORCRAFT

AC20-152 DEVELOPMENT ASSURANCE GUIDANCE FOR

AIRBORNE ELECTRONIC HARDWARE

CFR 21 CERTIFICATION PROCEDURES FOR PRODUCTS

AND PARTS

CFR 29 AIRWORTHINESS STANDARDS: TRANSPORT

CATEGORY ROTORCRAFT

Amendment 5

3.2 USCG Design Data

Replacement LED indicators shall be a form fit replacement of the legacy indicators PARTS in table 3.2 and shall physically interface with current aircraft panels. Additionally, indicators shall interface electrically requiring only minimal aircraft wiring changes to accommodate LED requirements. Current indicator design is made up of a light body and light capsule however the newly designed indicator can incorporate both the body and capsule into one unit.

USCG Technical Data Documents:

TABLE 3.2 MH65 LEGACY INDICATOR PART NUMBERS

NOMENCLATURE CURRENT PART NUMBER

SWITCH ASSY, “1 2” Body: 525VR01D1T36BNY

Capsule: 18824-011

3.3 Availability of Government Documents

Refer to Federal Acquisition Regulation 52.212-1(i) for instructions on obtaining Government

Documents. FAA documents are available on the Internet at “www.faa.gov”.

3.4 Applicable Commercial Documents

Unless otherwise specified herein, the Contractor shall comply with its own internal written standards relative to design, quality, and configuration specifications. The following are acceptable commercial standards:

RTCA:

DO-160 ECM LAB TESTING

SAE:

AS25050 Rev. A COLORS, AERONAUTICAL LIGHTS AND

LIGHTING EQUIPMENT, GENERAL

REQUIREMENTS FOR

AS18012 MARKINGS FOR AIRCREW STATION DISPLAYS,

DESIGN AND CONFIGURATION OF

AS50881 Rev. D WIRING, AEROSPACE, VEHICLE

ASME: Y14.100 ENGINEERING DRAWING PRACTICES

Note: Commercial documents must be ordered from commercial supply sources. The contractor shall utilize the most recent versions of documents that are published at time of award. The

Contractor shall identify the revision status and date of all references in their documentation.

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4.0 DESIGN CRITERIA

4.1 Airworthiness

The aircraft shall safely perform all assigned missions in accordance with FAA Part 29 (14 CFR

29) Airworthiness Standards: Transport Category Rotorcraft (Amendment 16), Part 91 General

Operating and Flight Rules and the USCG Air Operations Manual, COMDTINST M3710

(series). Modifications to the MH-65 must be designed to meet or exceed the requirements of

FAA FAR 29 & FAA FAR 21. Exceptions to FAA FAR 29 & FAA FAR 21 requirements are allowed for public use aircraft. Deviations from the FAA FAR 29 & FAA FAR 21 requirements must be approved by the USCG.

4.2 Wiring

Wiring shall conform to the requirements of SAE AS50881, Rev D. Kapton or PVC wiring shall

NOT be utilized.

4.3 Night Vision

New LED indicator assemblies shall be designed to be compatible with the use of a Type I, Class

B, Night Vision Imaging System (NVIS) IAW MIL-STD-3009.

4.4 LED Indicators

The assembly shall consist of two independent components, the switch body housing and the

LED indicator capsule. The LED indicator capsule shall be capable of field level replacement in the event of light failure without removal of the switch body housing from the panel.

LED indicators shall be a form fit replacement of legacy incandescent indicators and meet the indication and physical dimensions listed in table 4.1. Physical and electrical evaluation will be conducted at Aviation Logistics Center (ALC) upon delivery of First Article. Full production shall not begin until approval from the USCG, ALC SRR Engineering division approves the First

Article.

4.5 Precedence

In the event of a conflict or ambiguity, the following order of precedence among documents shall govern:

1. USCG specifications and procedures

2. Original Equipment Manufacturer (OEM) specifications and procedures

5.0 DEFINITIONS

5.1 Commercial Catalog Price

This price is derived from the most recent Contractor commercial catalog price.

5.2 Ready-For-Issue

The classification RFI indicates a part that is airworthy and ready for installation in a USCG aircraft.

5.3 Class II Configuration Change

A class II configuration change is a change that does not affect the form, fit or function of the component. A class II change will not affect the interface between the component and the aircraft. The parameters defined in the interface control document will not be changed. The following characteristics will not be affected by a class II change: Performance, Weight, Interface characteristics and Electromagnetic characteristics.

5.4 Government Furnished Information

Legacy light capsule body and housing part numbers identified in table 3.2 shall be used to ensure newly design indicators will be a form fit replacement of legacy parts. The government is unable to provide drawings of current components, but dimensional requirements are the same as the legacy parts and are also identified in table 7.2 in paragraph 7.2.

6.0 TECHNICAL DESCRIPTION

6.1 Performance Specification

NVIS compatible LED indicator assemblies listed in Table 7.2 in paragraph 7.2 shall be designed and manufactured in accordance with the design criteria listed in this SOW. NVIS capability is used routinely to execute USCG missions. Interior and exterior system compatibility is required to ensure that the aircrew can safely and effectively carryout their mission.

6.2 NVIS Compatible LED Indicator Product Description

The Contractor shall provide a complete technical description of the NVIS compatible LED indicator assemblies offered to meet this specification. The Contractor shall utilize their own internal standards in the development of the product description. The Contractor shall provide an individual description for each LED indicator assembly. The product description shall include all technical data necessary to completely describe the LED indicator assemblies. This description is expected to include the manufacturer’s technical drawings, references, and any additional information required to define the product. The technical description shall list at least the following data:

6.2.1 Manufacturer’s Technical Drawings

The manufacturer’s technical drawings shall include the following data:

• Any additional data required to completely describe the LED indicator assembly’s design/layout.

• Manufacturer’s part number and any other configuration tracking information.

• Individual replacement parts description including replaceable /LEDs and electrical connectors.

• Electrical data: Power consumption.

• Weight and Balance (weight & center of gravity).

6.3 Interface Definition

Aircraft Electrical Power Requirements: The NVIS LED indicators shall operate from a variable

13 VDC – 28 VDC power source with a per-capsule current draw not to exceed 50 MA at maximum intensity.

6.4 Performance and Capabilities

The NVIS compatible LED indicator assemblies shall meet Military Standard, MIL-STD-3009, for Lighting, Aircraft, Night Vision Imaging System (NVIS) Compatible.

7.0 NVIS COMPATIBLE LED INDICATOR ASSEMBLY DESIGN

7.1 General

The data provided here-in is intended to include everything that a qualified manufacturer would need to manufacture NVIS LED indicator assemblies for the MH-65E. The Contractor’s First

Article delivery will be evaluated for design compliance.

7.2 NVIS LED Indicator Assemblies Production

The Contractor shall provide new production NVIS LED indicator assemblies to meet the physical and electrical specifications listed in Table 7.2. The Contractor shall provide all parts, material, labor, tooling, test equipment and facilities needed to produce NVIS LED indicator assemblies at the firm-fixed prices specified. The terms of this contract apply to subsequent part number changes for the same part. If the material and labor required to produce the part are significantly different from the original production, modifications may be issued for the new part numbers. All production activity will be performed in accordance with the OEM’s technical requirements as accepted by the USCG. No production units will be procured until after first articles have been approved by the USCG.

TABLE 7.2 LED INDICATOR SPECIFICATIONS

ITEM

DISCRIPTION

QTY PER

AIRCRAFT

NVIS

FILTER

LEGEND PHYSICAL

DESCRIPTION

PHYSICAL

INTERFACE

DIMENSIONS

10 PIN, LED

ARRAY,

NORMALLY OPEN,

MOMENTARY

CLOSED, DUAL

POLE/DUAL

THROW SWITCH

WITH 1 2

ETCHED FACE,

INDEPENDENTLY

ILLUMINATED W/

PHYSICAL DIVIDER

TO PREVENT

LIGHT

BLEEDOVER.

ALTERNATELY

USCG WOULD

CONSIDER A 6 PIN,

LED ARRAY,

NORMALLY OPEN,

MOMENTARY

CLOSED, SINGLE

POLE/SINGLE

THROW SWITCH

WITH 1 2

ETCHED FACE,

INDEPENDENTLY

ILLUMINATED W/

PHYSICAL DIVIDER

TO PREVENT

LIGHT

BLEEDOVER.

AMBER 1/2

H= .430 in. (+/-

.010)

W= .930 in. (+/-

.010)

L= 3.25 in. (+/-

.020)

7.3 Qualification and Certification

The Contractor shall maintain FAA or DoD certification for manufacture of NVIS LED indicator assemblies for aircraft for the entire duration of this contract. The Contractor shall provide immediate notification to the Contracting Officer upon loss of the required FAA or DoD certification.

7.4 Modification Special Tools and Test Equipment

The NVIS compatible LED indicator assemblies should be designed so that they may be installed and maintained without special tools or test equipment. If required, the Contractor shall provide special tools and test equipment required to support the replacement of NVIS compatible LED indicator assemblies. Special tools and equipment will be included on the discounted price list.

8.0 TECHNICAL PERFORMANCE ACCESS AND DISCLOSURE

8.1 Technical Performance General

Information provided under this paragraph will not be disclosed outside of the government without prior written authorization from the party that provided the data. Contractor personnel working for the Government will be considered part of the Government workforce and provided access to data under nondisclosure agreements. Technical performance disclosure shall be provided until the NVIS compatible LED indicator assemblies are retired from service. The

Government will ensure that nondisclosure agreements are signed prior to providing data under this contract.

8.2 Notification

The Contractor shall immediately notify the Contracting Officer upon identification of any quality issue, failure, or situation that could possibly affect the reliability of the NVIS compatible

LED indicator assemblies. Any significant reported quality issue or failure on the same or similar product reported by any operator will be disclosed to the USCG within 24 hours of notification.

8.3 Access

USCG personnel shall be provided access to relevant NVIS compatible LED indicator assemblies’ technical performance information developed by OEMs. Technical performance information includes information pertaining to flight safety, equipment reliability and delivery performance. Inquiries by USCG technical personnel shall be answered as soon as possible and in no case later than 24 hours after requested for flight safety issues. Access will be provided to review manufacturer quality assurance and engineering documentation as required to support

USCG flight safety investigations.

8.4 Technical Data

The USCG will utilize contractor-provided data as required to maintain the NVIS compatible

LED indicator assemblies. Within 21 days of delivery of the first set of production panels, the

Contractor shall provide one set of the technical publications listed in Appendix A. The contractor shall provide drawings, technical publications, publication updates, amendments, and related information, as requested by the USCG.

8.5 Format

The Contractor shall provide electronic copies of the technical data delivered in accordance with this SOW. The electronic copy will include the current publication's xml file, graphics files, folder structure, Document Type Definition (DTD) and Formatting Output Specification

Instances (FOSIs). When feasible, Documents and Graphics shall be formatted to facilitate translation into USCG standard publications using the USCG ALC compatible software as described below.

As an alternative, the Contractor may propose that the government accept data in the

Contractor’s format. In this case, the Contractor shall provide the Contracting Officer with a listing of their available data formats. The Contractor shall also provide a cost estimate for translating their data to the preferred ALC data formats listed below.

8.5.1 Documents

Documents that are primarily text shall be delivered as follows:

• XML file linked to applicable graphics in Autotrol Technical Illustrator-derived .cgm files that shall be capable of being accurately viewed, printed, and modified using

Arbortext Editor version 6.0M020.

• Adobe .pdf files that are electronically searchable.

• Graphics associated with these documents shall also be delivered separately per the following paragraphs.

8.5.2 Graphics

Graphics (drawing, wiring diagram, or illustration) shall be delivered as follow:

1. Drawings or wiring diagrams shall be capable of being accurately viewed, printed, and modified in:

a) CoCreate Drafting 2008, or

b) Earlier compatible version of One Space Designer in .mi file format; or

c) The latest version of Autotrol Technical Illustrator in .dg format.

2. Illustrations other than drawings or wiring diagrams shall be capable of being accurately viewed, printed, and modified using the latest version of Autotrol Technical Illustrator in .dg format.

8.6 Data Rights and Confidentiality

The government shall be provided limited rights as defined in FAR 52.227-14 (May 2014), Alternative II (Dec 2007) and IV (Dec 2007). The Contractor shall provide technical change orders (specifications, drawings, etc.) developed to implement the modification. Underlying supporting data is not required except that the Contractor must provide data required by the government in order to validate system performance and airworthiness.

The USCG may disclose data outside the government for the following purposes:

(i) Use (except for manufacture) by support service Contractors.

(ii) Evaluation by nongovernment evaluators.

(iii) Use (except for manufacture) by other Contractors participating in the

Government’s program of which the specific contract is a part.

9 QUALITY ASSURANCE PROVISIONS

9.1 Responsibility for Inspections and Tests

The Contractor shall establish an inspection system in accordance with FAA and/or DOD procedures for all components. The USCG reserves the right to review the Contractor operation and/or facilities at any time during the period of the contract.

9.2 Testing

The Contractor shall provide a first article inspection report upon delivery of all first article

NVIS compatible LED indicator assemblies described in this SOW. Inspection report shall include a copy of contractors Acceptance Test Procedure (ATP) to the Government for review.

The Contractor shall make available to the Government all acceptance test results. The ATP may be incorporated into the manufacturer’s publications.

9.3 First Article Testing

First article testing will be conducted at ALC to include physical fit and electrical checks of each indicator. Physical fit testing will be evaluated by building up a fully operation panel with new

LED indicators. Electrical conformance will be testing utilizing a bench top electrical analysis machine that will apply appropriate power to each indicator ensuring proper function. Any physical or electrical conformance issues will be reported to the contractor with 14 working days of delivery of First Article.

9.4 Preliminary Inspection

All parts produced or modified under the provisions of this contract must be airworthy and suitable for installation on USCG aircraft.

9.5 Final Inspection and Acceptance

Final inspection and acceptance of material under this contract shall be performed at destination by local Receiving personnel and will consist of count, condition, and verification that all required documentation has been provided. ALC considers components RFI upon acceptance.

Components determined to be non-RFI upon installation may be returned to the Contractor with a Quality Deficiency Report for repair at no additional cost to the USCG.

9.6 Configuration Management Program

The Contractor shall have an established Configuration Management Program with control systems in place for the NVIS compatible illuminated panels including configuration identification of each hardware item for the contract life. Changes other than Class II changes, will not be made without approval from the Contracting Officer. Changes other than Class II changes will be identified by the issue of a new part number.

9.7 Serialization

The Contractor shall follow their own procedures.