SATPC0034369 TAB 04 4 SOW REV..pdf

July 2023 RLC-8s, RLC-16s

SOW Rev -

STATEMENT OF WORK (SOW)

FOR THE MANUFACTURE OF THE

Cutter, Reefing Line, Orion Lanyard Actuated, 8 second

P/N SLH26101149-303

And

Cutter, Reefing Line, Orion Lanyard Actuated, 16 second

P/N SLH26101149-304

NASA Lyndon B. Johnson Space Center

March 2024

Contents

1.0 SCOPE

1.1 General

1.2 Background

1.3 Device Definitions

1.4 Manufacturing Sources

1.5 Item Quantity

2.0 APPLICABLE DOCUMENTS

2.1 NASA-JSC Device Drawings .................................................................................................................................... Error! Bookmark not defined.

2.2 NASA-JSC Informational Drawings .......................................................................................................................... Error! Bookmark not defined.

2.3 NASA-JSC Design and Performance Specifications

2.4 NASA-JSC Other Applicable Documents .................................................................................................................. Error! Bookmark not defined.

2.5 Other Applicable Documents

3.0 REQUIREMENTS

3.1 Design Requirements

3.2 Performance & Acceptance Requirements

3.3 Manufacturing Requirements

3.3.1 Lot Manufacturing

3.3.2 Gas for Cleaning

3.3.3 Shop Aids

3.3.4 Liquids Contamination Prevention

3.4 Propellant Requirements ............................................................................................................................................ Error! Bookmark not defined.

3.4.1 Unloaded Samples ...................................................................................................................................... Error! Bookmark not defined.

3.4.2 Unloaded Sample Identification .................................................................................................................. Error! Bookmark not defined.

3.4.3 Unloaded Sample Shipment ........................................................................................................................ Error! Bookmark not defined.

3.5 Government Supplied Equipment (GSE) and Components (GSC) ............................................................................. Error! Bookmark not defined.

3.6 Lot Acceptance/Certification Requirements

4.0 REPORTING REQUIREMENTS

4.1 Manufacturing Methods and Testing

4.2 Design and Fabrication of Tooling ............................................................................................................................. Error! Bookmark not defined.

4.3 Key Personnel ............................................................................................................................................................ Error! Bookmark not defined.

4.4 Conferences, Reviews and Surveys Requirements

4.4.1 Reviews

4.4.2 Surveys

4.5 Quality Assurance Requirements

4.5.1 Processes and Products

4.5.2 Record Retention

4.5.3 Procurement Controls

4.5.4 Raw Material Controls

4.5.5 Traceability

4.5.6 Problem Reporting and Corrective Action

4.5.7 Non-Conforming Material

4.5.8 Non-Conformance Repot (NCR)

4.6 Government Source Inspection

4.6.1 Mandatory Inspection Points (MIPs)

4.6.2 Witnessing of Testing

4.6.3 Notification of Testing

4.6.4 Discrepancy

4.7 Verification of Test Records & Manufacturing

4.8 Safety Requirements

4.9 Control of Inspection, Measuring, and Test Equipment

4.10 Program Status Report

5.0 DOCUMENTATION REQUIREMENTS

5.1 Control Documentation

5.2 Lot Acceptance Data Package

6.0 SHIPPING

6.1 Shipping Containers ................................................................................................................................................... Error! Bookmark not defined.

6.2 Shipping Instructions

6.2.1 Devices & Loaded Pyrotechnics

6.2.2 Documentation Deliverables

6.2.3 GSE

1.0 SCOPE

1.1 General

This Statement of Work (SOW) establishes the requirements for the procurement of the following devices:

• Cutter, Reefing Line, Orion Lanyard Actuated, 8 second: P/N SLH26101149-303

• Cutter, Reefing Line, Orion Lanyard Actuated, 16 second: P/N SLH26101149-

1.2 Background

The Orion Main and Drogue parachutes each use two stages of reefing (restriction of opening diameter) during deployment. The release of these reefing stages is controlled through the cutting of Kevlar© reefing lines by RLC. For each reefing stage of each parachute, redundant RLC are used to ensure the reefing line is cut as required.

1.3 Device Definitions

The devices are defined as follows:

• RLC (8s and 16s) consist of a mechanically initiated firing mechanism (with sear, bushing, spring, and firing pin), a cutter body, a delay column (with percussion primer, pyrotechnic delay, and output charge), cutter blade, anvil, and O-rings for environmental sealing of components within the body.

• RLC-8s have an 8 second delay column

• RLC-16s have 16 second delay columns

1.4 Manufacturing Sources

The Orion parachute system where the RLC’s are used are considered Crit I where failure to function, or inadvertent function, results in loss of life/crew. Crew safety is directly dependent on the critical function of these devices.

Due to the criticality of the RLC’s, contractors must undergo a rigorous vetting process before becoming qualified to manufacture these devices for NASA. Currently Roberts Research Laboratories (RRL) is the only qualified manufacturer of Reefing Line Cutters for the Orion vehicle.

1.5 Item Quantity

The delivery quantity will be 100 each of the above mentioned item(s). Lot number designators will be assigned by the NASA-JSC Contracting Officer’s Representative

(COR).

Note: The Contractor will need to manufacture additional units within each lot to account for attrition and Destructive Lot Acceptance Testing (DLAT). Typically, total quantity produced to satisfy delivery and DLAT requirements will be 100 deliverables + 20 to 25 units for DLAT/attrition.

2.0 APPLICABLE DOCUMENTS

The following documents are applicable to the manufacturing and testing of the RLC’s.

Drawings are available from the NASA-JSC Engineering Drawing Control Center (EDCC) at 281-483-4014.

2.1 NASA-JSC Drawing, Design, and Performance Specification

DOCUMENT REV DOCUMENT TITLE

SLH26101149 D Cutter, Reefing Line, Orion Lanyard Actuated

Source Control Drawing

2.2 Other Applicable Documents

DOCUMENT REV DOCUMENT TITLE

ISO/IEC

17025:2017

- General requirements for the competence of testing and calibration laboratories

In addition to the above table, SLH26101149 defines other applicable documents and standards for Orion RLC’s.

3.0 REQUIREMENTS

3.1 Design Requirements

The Contractor shall design the devices such that they conform to respective design specifications given in 2.1 NASA-JSC Drawing, Design, and Performance Specification.

3.2 Performance & Acceptance Requirements

The Contractor shall manufacture the devices such that they perform in accordance with the respective performance specifications given in 2.1 NASA-JSC Drawing, Design, and Performance Specification.

3.3 Manufacturing Requirements

3.3.1 Lot Manufacturing

The Contractor shall manufacture the lot in continuous manufacturing process. All piece parts within a production lot shall be manufactured or procured from a single lot.

Note: A Lot is a group of pyrotechnic devices containing components which have the same design, construction, and material, fabricated (controlled by one unchanged set of baseline documents) in an essentially continuous manufacturing process (i.e., no manufacturing interruption exceeding thirty (30) days). A change in qualified personnel and equivalent equipment is allowed during manufacture of a lot.

3.3.2 Gas for Cleaning

The Contractor shall not use shop air, defined as compressed air not filtered and dried, for cleaning purposes.

3.3.3 Shop Aids

The Contractor shall not use debris generating shop aids during manufacturing.

3.3.4 Liquids Contamination Prevention

Except for the liquid used to make the slurry, the Contractor shall control liquids so they do not come in contact with the explosive mix. To prevent contamination of the explosive material(s), the Contractor’s applicable manufacturing procedures shall specify and verify the following:

• The immediate area of explosive loading shall be free of methanol, Freon, solvents and alcohol.

• Prior to loading any explosive material, each component shall be completely dry.

• After the loading any explosive material and prior to sealing, liquids shall not to be utilized for cleaning or sealing preparation.

• After sealing and prior to leak testing, if liquids are used to clean a loaded unit, any unit failing leak testing shall not be reworked, and the unit shall be rejected.

• In the event that spillage of explosive material necessitates cleaning of the loading area with liquids, all parts must be removed from the area until after such cleaning is complete, the area is completely dry, and the liquids have been removed.

3.4 Lot Acceptance/Certification Requirements

The Contractor shall submit the lot for acceptance to NASA-JSC after completion of all manufacturing, acceptance testing, and data reviews. The Contractor shall package the devices for shipment after completion of the final phase review. The contractor will provide an assembly level certificate of compliance with the requirements per

SLH26101149.

4.0 REPORTING REQUIREMENTS

4.1 Manufacturing Methods and Testing

The Contractor shall delineate the manufacturing and testing requirements in the appropriate Contractor documents (e.g. drawings, procedures, specifications). These documents shall be approved by the NASA-JSC COR and Safety & Mission Assurance (S&MA) representative prior to, or during, the phase review establishing the control documentation. Any changes to these documents after the phase review shall have COR and QE approval prior to use of the new revision. The Contractor shall make available these documents per Section 5.1.

4.2 Conferences, Reviews and Surveys Requirements

The Contractor shall support conferences, reviews, and surveys including corrective action and recurrence controls as specified herein. These reviews and surveys shall be conducted at Contractor facilities and will be chaired by the NASA-JSC COR. The Contractor shall also prepare and make available to the attendees all documentation necessary to accomplish the intended objectives.

4.2.1 Reviews

The Contractor shall support the following reviews with the necessary documentation and personnel. All reviews shall be conducted by NASA-JSC at the Contractor facility unless other arrangements are approved by the COR.

• Phase I, Baseline Review: A Baseline Review shall precede the start of manufacture of any lot of devices. This review shall include the “Control Documentation” referenced in Section 5.1. As part of the baseline review the contractor shall provide a certificate of compliance with the 10 year design life requirement as defined in SLH26101149 section 4.8 Design Life (DRD 1).The drawings, specifications, parts lists, and/or procedures established as a baseline (control) set by the Phase I review shall become a part of this SOW. NASA-JSC will direct the Contractor with the authorization to proceed with the manufacture of the components for production following this review and the closeout of open review items.

• Phase II, Production Review: A Production Review shall precede the start of manufacture of production lot of RLC’s. This review shall include any changes to the “Control Documentation” referenced in Section 5.1. This review shall assure adequate evaluation and control of all proposed changes to the baseline and/or last production lot, including the potential effect of the changes upon the qualification status of the devices. The drawings, specifications, parts lists, tooling, and/or procedures established or any changes during the Phase II review shall become a part of this SOW.

• Phase III, Lot Acceptance/Certification Review: A Lot Acceptance Review shall be conducted after RLC’s have been manufactured and presented to NASA-JSC for acceptance. This review shall assure that the intent of the Phase I Baseline Review and the Phase II Production Review have been successfully satisfied. The Contractor shall provide the “Lot Acceptance Data Package” in Section 5.2 (DRD 2) and any other applicable documentation requested during the review. The Government shall perform a detailed critical review of all manufacturing, inspection, and acceptance data and records. Acceptance/Certification will based on successful completion of the review.

4.2.2 Surveys

The Contractor shall support the following surveys with the necessary documentation and personnel. All surveys shall be conducted by NASA-JSC at the Contractor facility unless other arrangements are approved by the COR. For surveys that contain recommended actions, the surveyed organization shall respond within thirty (30) days after receipt of the survey report and submit a status report every thirty (30) days thereafter until all actions are closed, per DRD 3.

• Safety & Mission Assurance (S&MA) Survey: The purpose of this survey is to review all safety, reliability, and quality assurance documentation. NASA-JSC reserves the right to conduct surveys at any time during the contract. The Contractor shall provide data verifying internal conformance to the S&MA requirements upon request. The Contractor shall establish a schedule of Sub- Contractor SR&QA surveys and shall maintain records of results of surveys which shall be made available to NASA-JSC upon request.

• Contract & Task Requirements Survey: The purpose of the survey is to review all contract or task requirements. NASA-JSC reserves the right to conduct one (1) survey at any time during the contract and/or once every twelve (12) months for contracts that exceed twelve (12) months in duration. Thirty (30) days prior to the survey, the CO or COR shall notify the Contractor in writing of the intended survey. This survey will not exceed one (1) week (five (5) working days) duration.

• Incremental Survey: The purpose of this survey is to review only a specific area such as a process control problem or any other unsatisfactory detail that could be of such magnitude that the resulting hardware would be unacceptable to NASA- JSC. NASA-JSC reserves the right to conduct an incremental survey at any time to support the resolution of a specific problem. One (1) week (five (5) working days) prior to the incremental survey, the CO or COR shall notify the Contractor either by telecon or writing of the intended survey.

4.3 Quality Assurance Requirements

4.3.1 Processes and Products

The Contractor (and Sub-Contractor designated “critical processes”) shall document changes affecting processes, production equipment, tools and programs. The Contractor shall notify the NASA-JSC COR of proposed changes in process definition and shall obtain approval from the customer prior to implementing the change. The Contractor shall make the documents available for review upon request.

4.3.2 Record Retention

The Contractor and Sub-Contractors shall maintain verifiable objective evidence of all manufacturing, inspections performed, tests performed, results obtained, and dispositions of non-conforming articles. These records shall be identifiable to associated articles, by heat and lot number of materials, unit or lot serialization, and/or other traceable documentation. The Contractor and Sub-Contractors shall make the records available to NASA-JSC upon request. The records shall be retained in a safe, accessible location for a period of ten (10) years after date of delivery as defined in the contract.

Note: For use in human space flight, the materials, manufacturing, and workmanship of highest quality are essential to astronaut safety. If the Contractor or Sub-Contractors are able to provide the desired item with a higher quality than that of the items specified or proposed, the Contractor and Sub-Contractor are requested to bring this fact to the immediate attention of the customer.

4.3.3 Procurement Controls

The Contractor shall control and maintain procurement documents to ensure compliance with applicable quality and technical requirements. The procurement documents shall be submitted per Section 5.2 (DRD 2). The Contractor procurements shall include the following:

• Certificate of Compliance (C of C): The Sub-Contractor shall provide a certification with each shipment to attest the parts, assemblies, subassemblies, or detail parts conform to the Order Requirements. The certification should include order number, product name, part number, name and address of manufacturing or processing location, product identifiers (e.g. lot, heat, batch, date codes, serial numbers), quantity, unit of measurement and be signed and dated by an official of the company.

• Raw Material Test Reports: For raw materials, the Sub-Contractor shall provide chemical analysis reports, physical test reports and/or performance test reports.

The test report should list the specification, including revision numbers or letters, to which the material was tested and/or inspected and the identification of the material lot to which it applies.

• Age Controlled and Limited-Life Products: For articles and materials having definite characteristics of quality degradation or drift with age, the Sub-Contractor shall provide records that indicate the date and test time or cycle at which useful life was initiated, the life or cycles used, and the date, test time, or cycle at which the useful life is expended.

4.3.4 Raw Material Controls

The Contractor or Sub-Contractors shall inspect and/or test raw materials (e.g. chemical and/or physical analysis and/or performance testing) to determine conformance to applicable drawings and specifications. The reports of actual test results shall identify the particular materials tested. When material specification requires quantitative limits for chemical, mechanical, or physical properties, the test report shall contain the actual test and/or inspection values obtained. When material is altered, the Contractor shall submit all pre and post conversion chemical and/or physical test reports. Raw material shall be segregated and controlled to prevent the use of materials that do not conform to specifications or while awaiting completion and receipt of satisfactory test results.

4.3.5 Traceability

The Contractor shall develop a system to ensure identification of all materials/products, whether separately produced discrete items or material produced in batches, are traceable to the original source/manufacturer and are verifiable. This system shall be maintained throughout the life of this contract, including material/product receipt, all stages of production, delivery, and installation for twenty (20) years past the delivery date.

4.3.6 Problem Reporting and Corrective Action

The Contractor shall provide and maintain a closed loop reporting system involving the Contractor and Sub-Contractors for the reporting of all problems (failures, unsatisfactory conditions, and material review records). The Contractor shall insure that problem reporting, analysis, resolution, and status comply with JSC 28035 and be accomplished in accordance with DRD 4.

• Immediate Notification: The Contractor shall report all problems that occur during or subsequent to acceptance to the NASA-JSC COR within 24 hours of occurrence or detection. The Contractor shall also report any problems that occur prior to acceptance testing that will, or have the potential to, adversely affect safety, contribute to the delay of a scheduled event, or result in a design change, to the NASA-JSC COR within 24 hours of occurrence or detection.

• Problem Analysis: The suppler shall perform an analysis of each problem reported to determine the cause of the problem and to implement adequate measures to prevent its occurrence. A Contractor shall submit a formal analysis report to the NASA-JSC COR within 14 days of reporting the problem.

• Problem Resolution: The Contractor shall document efforts to determine the cause of a problem and the corrective action and implementation in a formal report. The Contractor shall submit the formal report to the NASA-JSC COR and must be approved prior to removal from the Problem Status List.

• Problem Status List: The Contractor shall maintain a list of all open problems.

The status list shall be submitted per Section 4.10 (DRD 6).

4.3.7 Non-Conforming Material

The Contractor shall report non-conformances to the customer involving any Contractor and Sub-Contractor materials and/or parts as soon as detected and determined not to be re-workable and may be salvageable. The Contractor shall notify the NASA-JSC COR within three (3) working days after the non-conformance is discovered.

Note: The customer grants no authority to disposition product or process non-conformances to the Contractor or its Sub-Contractors. Repair is not allowed under this clause.

4.3.8 Non-Conformance Repot (NCR)

The Contractor shall provide the NASA-JSC COR with a copy of the NCR or comparable report (e.g. Material Review Report (MRR), Discrepancy Report (DR), etc.) for review.

The COR shall coordinate with the cognizant NASA-JSC Quality Assurance personnel to review the NCR. The NASA-JSC COR shall provide written notification to the Contractor of NCR approval/rejection. All NCR dispositions shall be approved by the NASA-JSC COR prior to use (except scrap and return to vendor) per DRD 5.

Note: A contingent review of the NCR can be obtained by telephone from the COR;

however, use of the material prior to formal approval is at the Contractor's risk.

4.4 Government Source Inspection

The Contractor shall comply with the following Government Source Inspection requirements.

4.4.1 Mandatory Inspection Points (MIPs)

The Contractor shall incorporate Mandatory Inspection Points (MIPs), identified by the NASA-JSC Quality Engineer (QE), into Contractor applicable manufacturing and test procedures developed as part of this contract.

4.4.2 Witnessing of Testing

The Contractor shall allow a NASA-JSC representative or NASA-JSC designated witnesses to observe any and all testing.

4.4.3 Notification of Testing

The Contractor shall notify the NASA-JSC COR (or approved representative) a minimum of forty-eight (48) hours in advance of intended subject testing of the test procedures specified herein. The Contractor shall only perform MIP identified testing in the presence of a NASA-JSC approved representative.

4.4.4 Discrepancy

The Contractor shall immediately contact NASA-JSC COR in the event that a Government representative witnessing testing has identified any incompatibilities between hardware, processes, and/or technical requirements. The Contractor shall immediately initiate a non-conformance action in the case of discrepant hardware or request contract change if required to eliminate any incompatibilities.

4.5 Verification of Test Records & Manufacturing

Verification of Quality Control Surveillance shall be indicated by the identifying mark (inspection stamp) of the Government/Contractor Quality Control personnel or authorized delegates on the test data sheets as applicable.

4.6 Safety Requirements

The Contractor shall adhere to the following safety requirements.

• The Contractor shall comply with all federal, state, and local codes and standards applicable to work performed on this contract.

• In the event of serious injury or illness to personnel or damage to equipment and/or property arising from this contract, the Contractor shall notify the Occupational Safety & Institutional Assurance Division, code NS, at 281-483- 7500 (Safety Action Hotline), within twenty-four (24) hours of such occurrence.

The Contractor shall conduct an investigation into the causes of the accident and implement corrective measures. However, NASA-JSC reserves the right to conduct investigation into such occurrence as necessary. The Contractor shall provide support as required.

• The Contractor shall perform hazard analyses in sufficient depth to identify and correct conditions which could cause serious personal injury or illness, or significant damage to property limited to manufacturing and processing of toxic materials, test facilities systems, test set-ups, test operations, radio frequency hazards, auto-ignition temperatures, pollution, and environmental contamination.

4.7 Control of Inspection, Measuring, and Test Equipment

The Contractor shall have a documented calibration system that meets the requirements of ISO/IEC 17025:2017 Requirements for Calibration of Measuring and Test Equipment.

4.8 Program Status Report

The Contractor shall provide the COR with a monthly status update in accordance with DRD 6. The Contractor shall include the following at a minimum:

• Schedule

• Production Status

• Open Action Items

• Upcoming Reviews

• Problem Status List

Note: The monthly status report may be replaced by weekly meetings with Contractor provided minutes at the discretion of the COR.

5.0 DOCUMENTATION REQUIREMENTS

The Contractor shall furnish documentation as set forth in the Data Requirements List (DRL) and the Data Requirements Documents (DRDs).

5.1 Control Documentation

The Contractor shall provide or make available for review to NASA-JSC the record set of all documents pertaining to the materials, manufacturing, quality control, and acceptance of the device.

• The record set shall include all drawings (including tooling), quality control procedures, process specifications (with the exception of proprietary mixing processes), manufacturing specifications, key personnel, and any other documentation used in the production and testing of the devices.

• The record set shall also include all changes to the documents and a corresponding change-effectivity matrix.

• The record set shall establish the baseline for the production of the devices and shall be maintained throughout the duration of the contract.

• Each document, within the record set, shall be approved by the NASA-JSC COR prior to implementation.

• The Contractor shall provide a document list that includes the document number, title, revision number, and revision date of all documents in the record set. This document list shall encompass both Contractor and Sub-Contractor documents and revisions thereto.

• The Contractor shall provide NASA-JSC with one copy of each approved document within the record set.

5.2 Lot Acceptance Data Package

The Contractor shall provide NASA-JSC a lot acceptance data package per DRD 2. The Contractor shall make the lot acceptance data package available for review by the NASA- JSC representatives during at the lot acceptance review (Phase III). The Contractor shall ship the lot acceptance data package to NASA-JSC after acceptance of the lot. The lot acceptance data package shall include the following at a minimum:

• Certified acceptance reports including the date of manufacture of the devices in the lot and the lot number of the explosive material utilized.

• Certified list of all detail piece parts by their applicable drawing numbers, including revision letters. Receiving inspection records with numbers of units acceptance, to provide lot production and/or rejection traceability.

• Phase Review Meeting Minutes

• Documented final inspection records, including the original set of X-Ray and N-

Ray films of each part in the lot, with copies of the N-Ray and X-Ray certification prepared by the performing vendor.

• Copies of destructive lot acceptance data, including copies of the pressure/time traces and any other applicable data.

• Copies of raw material test reports.

• Statement certifying the formula of each explosive mix contained in each unit is the same used for qualification.

• The recorded weights including pre-load and post-load weights of each increment of the explosive mix.

• Copies of all nondestructive lot acceptance data including leak test information, and any other applicable data.

• Copies of all failure and corrective action records (e.g. NCRs, MRRs, DRs, waivers, deviations, etc.).

• A copy of the explosive classification. The Contractor of each pyrotechnic device shall be responsible for obtaining the explosive classification for that device from the U.S. Department of Transportation.

• A copy of the Competent Authority Approval. The Contractor of each pyrotechnic device shall be responsible for obtaining the Competent Authority Approval Letter, for that device from the U.S. Dept. of Transportation.

• A copy of the Material Safety Data Sheet. The Contractor for each pyrotechnic device shall be responsible for obtaining the Material Safety Data Sheet on the current OSHA form designated for that device being presented for certification.

• Contractor certificate of compliance as described in 3.6.

• Receiving inspection records of piece parts with material and process certification data sheets.

• Vendor certification records pertaining to material traceability from raw stock.

• A copy of each completed operational/manufacturing record (traveler) used in production of subject lot with inspection stamps therein denoting acceptance.

6.0 SHIPPING

6.1 Shipping Instructions

6.1.1 Devices & Loaded Pyrotechnics

The Contractor shall ship all deliverable devices to:

NASA/Lyndon B. Johnson Space Center Transportation Officer, Bldg. 420

2101 NASA Parkway Houston, TX. 77058

Attn: Jason Wolinsky / EP6 / B352 / 281-244-6956

6.1.2 Documentation Deliverables

The Contractor shall ship all deliverable documentation, including N-Rays Films, to:

NASA/Lyndon B. Johnson Space Center Transportation Officer, Bldg. 420

2101 NASA Parkway Houston, TX. 77058

Attn: Jacob French / EP3 / B15-R126 / x36614

6.1.3 GSE

The Contractor shall return GSE to:

NASA/Lyndon B. Johnson Space Center Transportation Officer, Bldg. 420

2101 NASA Parkway Houston, TX. 77 058

Attn: Refer to JF290 Block 1 / B352

Note: For return shipments to JSC, include a copy of the JF290. A copy of the JF290 will be shipped with the hardware and can also be requested from the COR.

3.4 Lot Acceptance/Certification Requirements