Attachment__1_Quality_Documents.pdf

Landing Gear SOW Quality Requirements

- 1 -

Page 1 of 10 Quality Assurance

1. General Requirements

The Contractor shall be a FAA approved repair station with appropriate rating to perform overhaul of Heavy Landing Gear and have implemented a Quality

Management System (QMS) that is compliant to the requirements of International

Aerospace Quality Standard AS 9100.

Prior to contract award the government may perform an on-site Quality Management

System Audit to verify QMS compliance to the AS 9100 standard.

2. Procurement Quality Requirements

The Contractor shall comply with the NASA Armstrong Flight Research Center

Procurement Quality Requirements Q-1A, C, and E, Q-2, Q-3, Q-4, Q-6, and Q-10

(QA Attachment)

3. Contractor Quality Assurance Plan/Manual

Contractor shall submit their Quality Plan/Manual with their proposal.

The QA manual/plan shall identify the supplier’s management policies, standard practices, job instructions, and work instructions. The manual shall describe requirements for quality, including failure reporting throughout all areas of contract performance, including fabrication, processing, assembly, inspection, test, packaging, storage, and shipping. The manual shall detail the complete flow of material from receipt to final shipment and may include flowcharts if available. If workmanship standards and/or manufacturing process differences exist between flights and non- flight hardware, the Quality Manual shall clearly identify these differences.

4. Documentation

The Contractor shall ensure the generation and delivery of all documentation as called for in this Contract.

In addition to that documentation specifically called for in the Contract, upon request by the NASA COR, the Contractor shall make available a copy of any document or data generated during this contract performance for review by NASA at either the Contractor's facility or via the internet. This includes, but is not limited to, technical reports and memorandums, tooling drawings, studies, analyses, parts and materials data, test data.

5. Pre-Ship Review (PSR)

The Contractor shall hold a Pre-Ship Review at the Contractor's plant at the completion of verification tests by NASA and prior to shipment of the hardware to NASA. A PSR shall be held prior to the delivery of each assembly. Any differences between the assemblies to be delivered and the drawings or specifications shall be listed and acceptance justifications presented. All discrepancy report documentation is to be discussed and included as part of the Data Delivery Package (described below).

- 2 -

Page 2 of 10 Quality Assurance

At the time of the PSR, documents and analysis to support satisfaction of the requirements of this SOW for the assembly being delivered shall be complete and all actions from previous reviews for the assembly being delivered shall be closed.

A Data Delivery Package shall be presented for review at each PSR. The Contractor shall deliver objective evidence with the assembly, showing product assurance acceptance of in-process workmanship processes, and final inspection. The Contractor shall implement all corrective actions necessary to remedy, before final acceptance, any nonconformance with respect to this SOW or the specifications noted on the design drawings. A government source inspection shall be required prior to shipment. NASA shall have final approval authority over all tests, verification, and documentation.

6. Data Delivery Package

The Data Delivery Package (DDP) is the primary quality record that documents the hardware deliverables were manufactured from specified materials, using specified processes, and meet the physical requirements of the drawing package. The DDPs shall be made available for review at the pre-ship review for each of the different assembly deliverables. A DDP is required for each assembly as well as each manufactured component within the assembly as each item progresses through the manufacturing process. At the time of assembly, the component level DDPs are combined with the

Assembly DDP. These documents shall be maintained at all times and made available upon request by NASA Quality representatives. The DDP package shall be comprised of, but not limited to, the following data:

Final Drawing Package- includes drawings and part lists updated to the current revision, rework instructions, change orders, and discrepancy reports, if any.

NASA will be responsible for updating any drawings and the Contractor shall be responsible for updating parts lists.

Manufacturing Process Traveler (see paragraph 3.2.2) - includes inspection sign-off for each process step.

Non-Conformance Reports (NCRs) - includes disposition status

Material Data Package – includes List of Materials with Lot Numbers, Expiration

Dates (when applicable), Certificates of Compliance (C of C), Material Test

Reports and FAA Forms 8130 for all components.

Dimensional Inspection Reports and Completed Travelers – stamped/signed quality control document including inspection.

Open Items List - documents reason for item(s) being open and proposed closure date

Life Limited Components List

A complete list of all Airworthiness Directives, Service Bulletins, and Service Letters

Embodied. Submittals to Boeing with Boeing Response (if applicable).

7. Surveillance of the Contractor

The work activities and operations of the Contractor, Subcontractors, and suppliers are subject to evaluation, review, survey, and inspection by the NASA/COR and representative(s).

The Contractor shall provide the NASA representative(s) with documents, records, and access to workings areas within the Contractor facilities that are required by the representative to perform the overview activities.

- 3 -

Page 3 of 10 Quality Assurance

8. Government Source Inspection

The Government may elect to perform inspections at a supplier's plant. The following statement shall be included on all procurement documents: "All work on this order is subject to inspection and test by the Government at any time and place”.

The Government quality representative who has been delegated NASA quality assurance functions on this procurement shall be notified immediately upon Contractor receipt of any supplier or Subcontractor orders. The Government representative shall also be notified 14 days in advance of the time that articles or materials are ready for inspection or test.

9. Contractor Source Inspection

The Contractor shall ensure that its procurement documents impose the applicable requirements on subcontractors and other suppliers. The Subcontractor and other suppliers shall in turn impose the requirements on their procurement sources.

The Contractor shall perform source inspection at the Subcontractor's or supplier's facilities in accordance with the contract or subcontract documentation or when one or more of the following conditions exist:

In process, end item controls, or tests that are destructive in nature prevent the Contractor from verifying quality after delivery to the Contractor's facility.

It is not feasible or economical for the Contractor to determine the quality of procured articles solely by inspections or tests performed at the Contractor’s facility.

Qualification tests are to be performed by the Subcontractor or supplier.

Products are shipped directly from the source to NASA, by-passing the Contractor's inspection facilities.

10. Notification of Government Mandatory Inspection Points (GMIP’S)

The Contractor shall notify the SOFIA Quality at least fourteen (14) calendar days in advance of all mandatory hardware inspections, test activities, and deliveries at either the

Contractor’s or a Subcontractor’s facility to allow timely participation by the NASA

Quality personnel.

The NASA/COR or representatives will perform the following MIPs listed below. The government may request additional MIPs if a specific process prohibits inspection at a later time or if the Contractor proposes a new process or specification.

Pre-Ship Inspection / Data Review

NASA reserves the right, after review of the Contractor’s planned inspection points, to add mandatory inspection points as determined necessary by the NASA Quality personnel.

11. Configuration Management

The Contractor’s Configuration Management (CM) system (available for review on request) shall control the design and hardware by means of drawings, specifications, and other documents and shall ensure all applicable changes are reviewed in a systematic manner to determine the validity and impact on performance, schedule and cost.

- 4 -

Page 4 of 10 Quality Assurance

Any flight item that is found to be non-compliant with the quality, workmanship and performance requirements of the contract shall be dispositioned via a waiver or deviation, unless the affected item is reworked to restore compliance or is replaced with a fully compliant item. The Contractor shall submit waivers and deviations to the COR for final approval.

Contractor QA activities shall be defined in the Configuration Management Plan and described in detail in the QA Plan.

Part numbering and a traveler system shall be proposed.

12. Nonconformance Reporting

All hardware non-conformances shall be reported to the NASA/COR and SOFIA Lead

Quality Assurance Specialist. They shall be notified within 24 hours of each non-conformance.

The Contractor’s processes for review, disposition and approval of non-conformances shall be described in their quality plan/manual or provided as a supplement document.

The contractor is not granted MRB authority. No repair, use-as-is, or scrap shall be done without written NASA approval.

These processes shall ensure that positive corrective action has been taken to preclude recurrence and that appropriate audits and tests are performed to verify the implementation of the corrective action.

For each reported nonconformance, there shall be a report that documents the investigation and engineering analysis needed to determine the cause and corrective actions to disposition the nonconformance, and identify any closed problem reports that do not have a definitive cause or corrective action. Reports shall be submitted to the NASA/COR and

SOFIA QA/QI for review and approval of the disposition. The supplier shall establish and maintain documented procedures to ensure products or components that do not conform to specific requirements are prevented from unintended use or installation. This control shall provide for identification, documentation, evaluation, segregation (when practical), disposition of nonconforming product, and for notification to the functions concerned.

13. Hardware Handling, Cleaning and Packaging

Qualified personnel working in accordance with approved procedures that address cleaning, handling, packaging, tent enclosures, shipping containers, bagging, and purging shall perform the handling of flight hardware. Compatible packaging shall be selected so that hardware is not contaminated or otherwise degraded during shipping or storage. All personnel working on flight hardware shall be certified as having completed the required training and competency certifications prior to handling any flight hardware.

Products shall be stored, preserved, marked, labeled, packaged, and packed to prevent loss of marking, deterioration, contamination, excessive condensation and moisture, or damage during all phases of the program. Stored and stocked items shall be controlled in accordance with documented procedures and be subject to quality audit. A certification log or traveler with all data from the assembly to delivery shall be delivered as part of

Deliverable Items List and Schedule package. The material certifications shall also be a part of the Deliverable Items List and Schedule.

- 5 -

Page 5 of 10 Quality Assurance

The completed assemblies shall be marked in accordance with MIL-STD-130, and shall include but not be limited to the following:

Vendor Part Number

Vendor Name

Vendor Serial Number

Contract Number

Unit Name

Weight

14. Shipping

Contractor is responsible for providing an acceptable shipping container that protects the hardware appropriately for all environments the hardware may encounter.

By executing the act of product shipment, the Contractor certifies that the product complies with all contract requirements. Prior to shipping, contractor Quality Assurance personnel shall ensure that:

Fabrication, inspection, and test operations have been completed and accepted.

All products are identified and marked in accordance with requirements.

The accompanying documentation (Contractor's shipping and property accountability form) has been reviewed for completeness, identification, and quality approvals.

Evidence exists that preservation and packaging are in compliance with requirements.

Packaging and marking of products, as a minimum comply with Interstate Commerce

Commission rules and regulations and are adequate to ensure safe arrival and ready identification at their destinations.

The loading and transporting methods are in compliance with those designated in the shipping documents.

Integrity seals are on shipping containers and externally observable shock or humidity monitors do not show excessive environmental exposure.

In the event of unscheduled removal of a product from its container, the extent of re-inspection and retest shall be as authorized by NASA or its representative.

Special handling instructions for receiving activities, including observation and recording requirements for shipping-environment monitors are provided where appropriate.

The Contractor’s quality assurance organization shall verify prior to shipment that the above requirements have been met and shall sign off appropriate shipping documents to provide evidence of this verification. The Contractor shall ship Freight On Board (F.O.B.)

Destination. The Contractor has the responsibility for any damage incurred during shipment.

15. GIDEP Alerts and Problem Advisories

Contractors shall keep sufficient selection and usage records for all flight parts, assemblies and materials adequate to determine applicability of any issued Government

Industry Data Exchange Program (GIDEP) alerts relevant to items used on the project.

The Contractor shall review and disposition all GIDEP Alerts for relevancy and impact. In addition, the Contractor shall review and disposition any NASA Alerts and Advisories provided to the Contractor by the NASA/ COR or designee. Alert applicability, impact, and corrective actions shall be documented and status provided to the NASA/COR on a

- 6 -

Page 6 of 10 Quality Assurance monthly basis.

16. Materials Procurement Requirements

Raw materials purchased by the Contractor and its subcontractors shall be accompanied by a Certificate of Compliance and, where applicable, the results of nondestructive, chemical and physical tests. This information shall be made available to the NASA/COR for review. Materials used shall be bought according the drawing package specifications.

The government shall approve any deviations of material types.

17. Process Selection Requirements

Manufacturing processes shall be carefully selected to preclude unacceptable material property changes during exposure to flight environments that could cause adverse effects to the material and/or to the intended applications. Materials and manufacturing process information shall be provided on the material list.

QA Attachment

- 7 -

NASA Dryden Flight Research Center

PROCUREMENT QUALITY REQUIREMENTS

Q-1

Section A: Aircraft Assemblies, Parts and Materials

Supplier shall only deliver aircraft assemblies, parts and materials that comply with the following requirements for new, surplus, used and or repaired articles. Concessions to these requirements may be granted, but only by the following:

a. Written authorization following review by the Government’s Ops Engineering

b. Procurement/Project specific Quality Assurance

c. Contracting Officer’s Technical Representatives.

Unless otherwise specified for delivery to the Government, all applicable material test reports, processing, overhaul, repair and maintenance certifications, inspection, test and non-destructive examination results shall be retained for at least 10 years by the supplier, and made available upon request.

Supplier shall ensure that articles conform to all original design and manufacturing requirements for materials, processing, inspection, test, non-destructive examination, marking, packaging, preservation and transportation.

For each article (New, Surplus, Used and/or Repaired) the supplier shall identify:

a. Manufacturer’s part number, and heat, batch or serial number (when applicable).

b. Manufacturer’s name, date of manufacture and street address of production facility and/or article’s maintenance repair or overhaul facility.

c. Proof of serviceability by the appropriate depot serviceable tag

d. FAA Parts Manufacturing Approval (PMA)

e. Technical Standard Order Authorization (TSO), Manufacture authorized to make item

f. FAA Form 8130-3

g. Verify that articles conform to all applicable requirements for materials, processing, inspection, test, non-destructive examination, marking, packaging, preservation and transportation.

h. Identify any article (if applicable) obtained from an aircraft that was subjected to extreme environmental or operational stress, suffered a major failure or accident or was operated by a non-U.S. entity.

i. Provide the implementation status of each applicable FAA Airworthiness Directive and manufacturer’s Service Bulletin.

j. Ensure that each component with a shelf life has been identified, including associated expiration dates.

- 8 -

Section B: Counterfeit Prevention of Electronic Parts

Supply Chain Traceability for Electronic Parts

In order to minimize the risk of procuring counterfeit product, the supplier shall ensure conforming, authentic material is provided. The supplier shall meet or provide the following:

a. The supplier shall provide full traceability for the parts being purchased, including names and addresses of prior sources (if any) to the buyer. The supplier shall maintain records containing date and/or lot codes, and any serialization associated with the purchase order and invoice according to DFRC Requirements.

b. Supplier shall provide documentation on product authenticity, including accept/reject criteria and qualification of test/inspection personnel. The supplier shall provide inspection and test reports demonstrating product conformance to NASA specified criteria.

c. The supplier will be in compliance or certified to at least one of the following Quality Management Standards (e.g., AS9100, AS9120, ISO 9001, and AS9003).

d. NASA is not under obligation to return suspect or confirmed counterfeit products.

These parts will be processed under the disposition instructions of NASA, GIDEP and/or FAA A/C 21-29 guidance.

e. The supplier shall provide certificates of conformance and test/inspection data upon delivery and prior to NASA acceptance of supplies ordered.

A certification of conformance is required for all custom parts. These parts require a Non Standard Parts Approval Report (NSPAR) prior to use. These parts are made from source control drawings (SCD). This type part includes any Electrical, Electronic or Electromechanical (EEE) part that that has been modified or is not used as intended.

Custom parts require build records, test data and destructive physical analysis (DPA) data accompany the parts.

All EEE parts affected by this attachment require trace ability from the manufacturing location by Cage Code to where the parts were made. Parts require full trace ability to lot, date code, and batch code type data.

All EEE parts must be incompliance with NASA-STD-8739, NASA-STD-8739.4, IPC-J- STD-001E and ANSI/ESD S20.20. (See attached)

Section C: Certification of Conformance

As part of each shipment, the supplier / manufacturer shall certify contract / order conformance to the Government.

Supplier shall provide traceability from the source or manufacture on all items shipped.

- 9 -

The Certification of Conformance shall:

a. Confirm that the supplier / manufacturer has verified the acceptability of all articles before shipment – by completion of the necessary inspections, tests, audits, process controls and records reviews.

b. Identify the contract / order number, and relevant line item number.

c. Identify the manufacturer’s part number, and heat, batch or serial number (when applicable).

d. Identify the shipped quantity and unit of measure.

e. Be signed by a duly authorized officer or quality representative of the supplier / manufacturer – whose name and title shall be legible.

Section D: Process Qualification and Control (Calibration)

For each calibrated tool, gauge, instrument or other calibrated device purchased by the Government, the manufacturer’s certified calibration report and Certification of Conformance shall be provided.

Each calibration report shall:

a. Identify a unique calibration report / tracking number.

b. Be traceable to the customer contract / order number.

c. Identify the device’s name, model number, and when applicable, its serial number.

d. Identify the manufacturer’s recommended recalibration frequency.

e. List the date of initial calibration.

f. List the calibration technician’s name.

g. List the relevant environmental conditions for each parameter calibrated.

h. Identify each standard that was used in the device’s calibration, including:

Each standard’s unique identifier, with NIST traceability.

The nominal value of each standard, as determined during its most recent calibration.

i. Record the value obtained by the device for each standard used in the calibration.

Section E: Delivery Requirements

To assure protection from damage during normal handling, transport, and storage after receipt, articles and materials shall be packaged and preserved in accordance with NPR

6000.1 – Packaging, Handling, and Transportation:

a. Level B – Preservation, Packaging, and Packing.

b. Class I – Shipping and Handling.

- 10

Marking shall include, as a minimum, nomenclature, part number, quantity, supplier, expiration date, temperature handling requirements and lot/batch information. A Certification of Conformance (CoC) is required.

Items containing hazardous materials shall have the manufacturer’s Material Safety Data Sheet (MSDS) included.

Articles or materials which have shelf life limitations or storage control requirements imposed by the manufacturer, Government, NASA or the contractor shall be accompanied by positive indication of such limits. Examples include manufacturing date, cure date, assembly date or temperature storage limitation.

Articles and materials shall have a minimum of seventy-five percent of the manufacturer's designated shelf life remaining at the time of shipment.

Approved 1 Jul 14

PQA